Rear Axle Leaking - 2.8l SWB

[Big-Bird]

Thankfully Pajero Differential housings and axle tubes can be welded. The only cast piece is the gear carrier and that can't be welded.

Your axle tube can be repaired but your problem will be finding a shop that will do it and given the size of the crack its likely the metal in that area has been compromised all around that circumference. As soon as it started to leak it should have been welded.....not sealed with JB weld or silicone and left alone. These are temp measures to reduce drips.

it might need to be taken apart and at the very least it will require not only a weld to seal the crack but a wide curved plate to strengthen the area all around.

Lots of 4x4 shops that do custom work like differential swaps can do this repair.....but the question is will they take on this project?

Don't let a weldshop feed you BS that your differential is cast and that it can't be welded. If you have a National 4WD shop nearby I would recommend calling them.

[str8gooods]

Thank you for the reply. The crack had been welded initially but not very well. I had a hard time finding anyone who would even attempt it, and at that point its was only a hairline. The jb weld came on after the weld started to seep oil. Everything escalated very quickly once the weld started to give out. Maybe I should at least go clean up the crack a bit with my angle grinder to clean up the jb and old weld. Make it a bit more presentable for a shop to work with.

[Feds]

car-part.com shows a few axle housings as close as Detroit. The axle from a 3.5 montero should bolt right in. Swap over your centre section to get the gearing right.

If you're seriously desperate or short on time, I just bought a JDM SWB that I was going to turn into a buggy. It's a 3.5, but the axle housing would fit even if the gearing is different. We could probably work something out for the axle on it.

[str8gooods]

Feds you may be a life saver. If you are willing to part with your rear end, I am more than interested. Seems you are only about an hour away from me as well. This is my daily driver so I would like to have her back up and running sooner than later. I'm going to grab some jack stands and get this one pulled out tomorrow. If you want to discuss it please feel free to call or text me 905-741-3282. Thanks in advance My name is Vincent.

[PHIL]

Hello everyone. I need some help. What was once just a leaking axle housing, has now become a cracked axle housing. Does this look weldable, or am I going to have to source a replacement housing. If so, anyone have any ideas where. I'm unsure of what montero stuff might fit. My truck is a 94 2800 with the lsd. Here's a pic.

crackedaxle2.JPG

Any help would be great

Sounds like you have this sorted. If it doesn't work out, a few more thoughts...

If you're looking stateside, you'll be wanting the Montero SR rear, that came with the 3.5L engine. This is the larger rear, like the 2.8. 94-97 should be all the same.

... the diesels typically use numerically lower gearing than the gas US Domestic Market Monteros. It would be really nice to be able to simply swap the whole rear, but you have to match diff ratios so check the tag on the firewall - it'll probably say 4.90 for the diff ratio. Most of the U.S. Monteros use 460 something's, although there was a high altitude gas version that used the same ratio. So certainly possible to get a U.S. Auto wrecker version...

But hopefully you have a source already.