When I built the Sub, I was on a tight budget but had standards and absolutely wanted to have a Detroit locker in the back. I could have gone a much less expensive route with a full spool, mini spool, lunchbox locker or even welding it, however after snapping two axles for separate but equally stupid reasons, I decided to shell out the $800 and get a real Detroit locker in the rear. I absolutely love it and will never ever even consider anything else for a daily driver dedicated trail rig.
I have also heard of Lincoln lockers or welding rear spider gears and always wanted to try it.
Here is how I did it on my Jeep Liberty without removing the carrier from the diff.
This is what all other instructional videos do not tell you:
It can be done with a 110V stick welder. I chose stick over my 110V wirefeed because Harbor Freight mirefeed welder has a ridiculous amount of splatter and it just does not penetrate nearly as well as a stick.
Cleaning out differential fluid takes a crap load of time!! at least two cans of brake parts cleaner, lots of wiping and scrubbing, oh yeah when you rotate the gears it re coats everything all over again.
Heating with a propane torch is vital for both burning off residual oil, brake parts cleaner and warming up the metal for a better weld. It took over 30 minutes of burning to burn off the diff fluid that I could not get out with wiping or wire brush.
Warming up 7018 welding sticks in a toaster oven for 4-6 hours at 200F makes welding smoother.
Welding just one side gear to carrier turns the rear end into a fully locked differential. Welding the other side gear to carrier increases the strength. Welding the spider gears to the carrier prevents any wiggle or play among the gears.
Welding the spider gears to each other is not necessary. Rear axles are only in direct contact with the side gears and as long as the side gears are welded securely to the carrier you have in turn made a reliable full spool out of your differential.
Before welding Chrysler 8.25"
Stick welded Chrysler 8.25" rear diff.
Bottom line is that it's not that difficult, cleaning and heating the metal takes at least an hour. Any dedicated non street driven trail rig I will ever own from now on will have a welded rear diff, which includes my 96 Tahoe plow truck.
Stay tuned for more shenanigans!
That's how they came in Mexico for 2003-2006.
