front diff crossmember cracks

[bonesXU1]

I spotted yesterday that where the bottom arm mounts to the diff mount/crossmember bolts together there were stress cracks both sides.
I have welded the cracks up and plug welded a 5mm plate in the offending area and thought I would mention it on the forum so other people can check theirs.
I only noticed it when I was going to grease my anti roll bar bushes and had removed the skid plate. Anyone else had this problem? as it could have been really bad if I hadn't spotted it .

 

[solarman216]

Pics would be good, Rick

 

[bonesXU1]

Pics would be good, Rick

I should have took some pics before the repair but I will take a pic of it now it is fixed. :doh

 

[solarman216]

I should have took some pics before the repair but I will take a pic of it now it is fixed. :doh

At least that will give us a positive location, never seen that before but then again not looked, be interested to see the pic, Rick

 

[bonesXU1]

Passengers side is fine and no problems with that just the drivers side seems to be cracked.
.

The crack was on both sides of the crossmember and I have highlighted in green where the cracks were. I have 4 plug welds and welds along the edges so it should be pretty strong now.
.

 

[solarman216]

Were the bolts the originals, you will know as you cannot get one on each side out as they came in from the rear and have to be cut, then new inserted from the front, Rick

 

[bonesXU1]

Were the bolts the originals, you will know as you cannot get one on each side out as they came in from the rear and have to be cut, then new inserted from the front, Rick

I had to take the torsion bar out to get the bolts out, bit of a pain but I have had the torsion bars off before so not too bad to sort out really. Torsion bar mount would have been in the way for welding so had to remove it anyway.

 

[solarman216]

I had to take the torsion bar out to get the bolts out, bit of a pain but I have had the torsion bars off before so not too bad to sort out really. Torsion bar mount would have been in the way for welding so had to remove it anyway.

OK so original bolts, unlikely for them to have come lose, so I will be checking all the T2s I have here for signs of cracking, this is a very serious place to have cracks develop, hope it is a one off, Rick

 

[terranosaurusdoug]

Have you been giving it some general lee, bones? :lol

 

[Blocky10]

That's bad news but good that you've shared. I'll be checking next time I'm under. Thanks :thumb2

 

[rustic]

That's bad news but good that you've shared. I'll be checking next time I'm under. Thanks :thumb2

Yes thanks for sharing, I would say that this is one of the most serious defects that we have had on our vehicles, had it broken, it could have been really serious.

What year is your vehicle, and how many miles?
What sort of life has it had?
What is the general condition of the chassie re rust and corrosion?
Has your truck been lifted?


Note for the Moderators
I think for the first time we need a new section in the forum, for serious defects, and it is easy to check, a visual inspection.

Thank you for sharing, :thumb2
it will be interesting if there are many more.
Uncle Rustic

 

[bonesXU1]

Yes thanks for sharing, I would say that this is one of the most serious defects that we have had on our vehicles, had it broken, it could have been really serious.

What year is your vehicle, and how many miles?
What sort of life has it had?
What is the general condition of the chassie re rust and corrosion?
Has your truck been lifted?


Note for the Moderators
I think for the first time we need a new section in the forum, for serious defects, and it is easy to check, a visual inspection.

Thank you for sharing, :thumb2
it will be interesting if there are many more.
Uncle Rustic

My Ter is 2001 and about 75,000 miles
I bought it with 38,000miles on the clock about 6 years ago and take good care of it, it goes on green lanes now and again but no competition use.
No rust or corrosion on the chassis to speak of, a bit of surface rust but not much ,it is solid and had very little use off road before I bought it.
It isn't lifted just re-indexed torsion bars to level it out and 31/10.50/15's fitted.

The only thing I can think that it may have had a wack a year or two ago on a hidden rock on a night green lane run that spun the wheel out of my hand.
It may have coursed a crack which may have taken time to spread.
But defiantly no General Lee style yeha jumps.

 

[jims-terrano]

Wire brush coming out to clean mine off later this week.