Hey guys,
1985 pickup, Xtra Cab, 1986 22re out of a 4runner, RUF'S, Marlin crawler 2x t-cases, front and rear auburn auto lockers.
This thread belongs here because I am basically updating this thing with modern SAS parts and will be cutting/welding quite a bit.
I'm in the middle of updating some suspension stuff. Mostly cutting out all of the previous owner's "budget build" nightmare.
I noticed when I pulled the front axle that there was some pretty serious dents in the front of the diff housing. Has anyone seen any carnage like this, or worse?



I was planning on pulling the 3rd to prep and paint the axle, so I'm afraid there might be some damage to ring gear or worse to my carrier/locker.
Any stories or experiences welcome.

 

It doesn't look that bad. I have armor on mine so the cover never bashed in at all. But the drain plug looked like that so I changed it to the socket head type.

You could probably pound out the dents from the inside with the diff out. Then add some armor.

 

i would go this route too. just closely examine your housing after removing the dents to make sure no cracks developed

 

As others have said, pull the 3rd and pound them out. Heat always helps when moving metal. Then weld on some armor. Dorman make new "stock" covers you can weld on too if you cant repair that one.

If you wheel enough the drain plugs become so smashed its easier to just weld them closed and grind them smooth, then just use a lower diff stud to drain fluid.

 

When you off road one has these little mishaps .

Since your pulling the differential inspect things
.From things I have worked on any dents impacting rotating parts will wear a hole through the cover in a short time. Like anything else weird things happen .