anyone bust off a front diff mount before?

mongoosevrx · 10-12-2009, 06:41 PM

Great site! After searching around, I'm starting a new thread. I have a U.S. 1993 tracker 2-door 4x4 with the 1.6l and a 5 speed. Off roading a couple weeks ago I just about fried a cv joint durring a hill climb. This past weekend i was replacing the half-shaft and noticed the ear mounting the front diff to the engine crossmember was cracked all the way through. When the diff is loaded, the bolts used to attach the shaft from the t-case to the yolk rub against the crossmember (and nearly shaved in half!). Has anyone broke this mounting "ear" before? What would you suggest for an easy fix? All I've come up with so far would be to make a bracket to run longer bolts through and wrap around the diff, or take the whole cover off and weld the two pieces back together(which I'm not too crazy about, being it's cast aluminum, and very thin, and it broke once already). Thanks

mongoosevrx · 10-12-2009, 07:47 PM

a picture from underneath with me holding the broken piece in place

mongoosevrx · 10-12-2009, 07:50 PM

and one with the mount in position

obradleyo · 10-13-2009, 12:14 AM

That is a pickle your in. I had ro replace mine, they usally break this way... I just looked for a link to help you but i couldn't find it. the guy makes a bracket that wraps compleatley around it

relicduke · 10-13-2009, 07:06 AM

M'lady broke our's in snowdrift last winter,I had some light chain that I tied it down with,left a little slack,just tight enough so it doesn't rub.I've towed some lesser vehicles,including a ford half ton out of a swamp,and it's holding up.
But then I've been known to be unconventional at times

mongoosevrx · 10-13-2009, 07:18 AM

[quote=obradleyo;189782]That is a pickle your in. I had ro replace mine, they usally break this way... I just looked for a link to help you but i couldn't find it. the guy makes a bracket that wraps compleatley around it

I think thats what I'll do. Is this a common problem? Thanks for the help!

mongoosevrx · 11-02-2009, 04:22 PM

Got it fixed up, the yellow piece attaches to the pivot bolt on the rear a arm mounting point then strapped it down.

I ended up with 2 extra brackets, if anyone wants one, let me know. You would need to "modify" the factory crossmember. I just grabbed the lip with a vise-grip and bent it down a little to fit the new piece(took 2 minuets).

Rhinoman · 11-03-2009, 03:02 PM

Is there anyone who hasn't? The only real solution is the steel diff casing and diff housing from a V6 GV or diesel model. Reinforcing the rear mount will just move the weak point elsewhere, the main housing will shatter next time.