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I have a rearend that is a terminal leaker where the axle tubes are pressed into the center section. I have heard of people welding the axle tubes to the center section to stop this but I have some questions. What type of welder is best for this? Are there any special prcedures considering that the center section is cast iron and the axle tubes are steel? Also, how much has to be removed from the rearend to prevent damage to the other parts from heat? TIA
 

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To the best of my knowledge the housing should have all internals removed then a heavy iron shaft with flanges on each end slide on to keep everything straight while weldind I would contact someone that shortens rear end etc for this some people just weld them but i would look into having done as described MIKE
 

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Listen to MIKE! Without the proper alignment set up the tubes will almost certainly get out of alignment. One company I called wanted $100 to weld my tubes unless they got out of alignment and then they would charge me another $250 to fix the problem!! I wondered why they just didn't do it right the first time and told them to forget it. In the most recent issue of Chevy High Performance I saw and ad for new 12bolt housings. I forget the name of the company.
 

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A guy I know welded my friends axle tubes where you mentioned, but not for the same purpose, his was for extra strength so it would'nt twist apart, that happened to another friend of mine, anyway, as long as you use a mig and weld 1-2 inch strips around this area and let eachsection cool before doing the next you won't have a problem.If you try to make a complete weld around the whole tube at one time it will get to hot and thats when you risk the chance of warpage or unbalancing of your tubes to your housing.
 

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as far as the two different metals,they make special welding rods for this application if your using arc and special wire for using mig.As for removing the insides,theres no need if you do it the right way.
 

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It can be done together yes it may work out ok but there is a chance of the tube pulling if you decide to weld it intact make sure wheels are off the ground so there is no pressure on the tube . I strongly recommend
some small tacks 180deg apart that will keep everything straight hopefully MIKE
 

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I welded my 12 bolt axle tubes in for strength. I had the rear out of the car, and welded in 1" long segments with a 220 volt Snap-On Mig welder. I would weld 1" on the left tube, then 1" on the other tube, then back to the first side for 1 more inch and so on. As long as you do small welds at a time and let them cool you should not have any problem.
 

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SS I've been a welder for many years now & don't know of any Mig wire that works well for this combo. There are rods avaliable from your local welding supply. But distortion is a real possibility. What about just brazing? That will clean up your leak with little movement. Just a thought. Make sure you empty the housing, and have everything well supported & braced before you start any welding though. Good luck!
 
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