Author Topic: weld it or replace it?  (Read 3293 times)

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hytenor

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weld it or replace it?
« on: Sep 19, 2015, 01:55:12 PM »
discovered a nasty crack in my steering box the other day :(



After consulting with another on this as to how it happened the best guess is that the mounting surface/frame was not quite flat on install. (all bolts kept to 100#, steering stops correct, etc...) and the cast has finally cracked from the stress over the last 9 years.

so, the question is to have it welded by someone who works with cast and do this on the truck in case the problem IS the non-flat mounting surface.
or, replace the box and figure out a way to get the frame rail flat or just shim that one ear...assuming this is the problem.

thoughts?

'00 Tacoma, 2.7, 4.7 crawler, 5.29s, 35s, PSC hydro assist kit with 6" ram

redneckcustoms13

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Re: weld it or replace it?
« Reply #1 on: Sep 19, 2015, 02:29:43 PM »
Personally, I'd weld it right where it is.
83 long bed 2wd sas, 3rz, w56, duals with 4.7 rear, 4.88 elock front, spartan rear, 39.5 iroks
01 double cab hunting truck
06 tacoma street truck

86bobbedtoy

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Re: weld it or replace it?
« Reply #2 on: Sep 19, 2015, 02:32:03 PM »
replace it, you don't want the cast welds to crack on the trail, or on the road at that

hytenor [OP]

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Re: weld it or replace it?
« Reply #3 on: Sep 19, 2015, 02:40:11 PM »
replace it, you don't want the cast welds to crack on the trail, or on the road at that

assuming the cause is from a non-flat surface where that one ear mounts...even if that one ear is only carrying just over a 3rd of the stress?  do you think there would be enough pressure to crack a cast weld once the thing is stabilized?  I'm no engineer but I don't see the stress levels doing that once that ear is welded and stabilized in its 'new' position.
That said, if the cause is due to something else then I'm absolutely replacing it.  The problem then will be determining what that actual cause is to prevent re-occurrence.

hytenor [OP]

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Re: weld it or replace it?
« Reply #4 on: Sep 19, 2015, 02:42:54 PM »
Personally, I'd weld it right where it is.

would there be enough heat to melt the seals if welding it as it sits?  I would certainly run no more than 1/2 to 3/4" beads between cool-downs.

There are no signs of any cracking or cracked paint stress lines on the other two ears.

redneckcustoms13

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Re: weld it or replace it?
« Reply #5 on: Sep 19, 2015, 07:06:54 PM »
Well, you actually need to pre heat cast before welding.

In this case however, I'd say tig it with a 309 weld real hot real fast but at the same time try to keep it cool. If that makes sense.
83 long bed 2wd sas, 3rz, w56, duals with 4.7 rear, 4.88 elock front, spartan rear, 39.5 iroks
01 double cab hunting truck
06 tacoma street truck

emsvitil

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Re: weld it or replace it?
« Reply #6 on: Sep 19, 2015, 07:42:26 PM »
Drill a hole at the end of the crack to stop the propagation of the crack.


Then decide if there's enough meat to leave it alone.....
Ed
SoCal
86 SR5 XtraCab
22RE  W56B
31x10.50R15

hytenor [OP]

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Re: weld it or replace it?
« Reply #7 on: Sep 20, 2015, 12:23:26 AM »
I plan on finding a good welder and driving the truck over for eval...probably Mon.

hytenor [OP]

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Re: weld it or replace it?
« Reply #8 on: Oct 01, 2015, 01:55:51 AM »
pulled the box...
cause:  not fill-welding around the sleeves...under the ear that cracked was about an 1/8" depression that the ear pulled into after 9ys :p
well, duh...
the opposite side was the same but hadn't cracked.
I filled the two depressions in and ground the surface flat and am having the box repaired by a local guy who has done a lot of cast.
should be good for another 9yrs :p

ironically I could probably have just done the repair to the plate mount...welding/grinding flush and then remounting the box and torquing it down...probably would have lasted longer than the truck will.

dt75flh

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Re: weld it or replace it?
« Reply #9 on: Oct 07, 2015, 08:47:26 PM »
usually you pre heat the cast..then slow cool in sand..you taking the box apart first?

hytenor [OP]

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Re: weld it or replace it?
« Reply #10 on: Oct 08, 2015, 03:48:29 PM »
usually you pre heat the cast..then slow cool in sand..you taking the box apart first?

didn't have to.  got it back today from a local welder with many years of cast experience...got lucky :p
He didn't try to bend the ear back to re approximate the crack as that probably would have snapped the ear off.  He V-grooved the crack and welded it up with 99% nickle rod after preheating the area to 350*.  1/2" beads at a time with peening during cool down after each bead.  It worked great.  I then was able to re-machine/flatten the mounting surface with fine grit wheel and big, flat mill b*std.  Paint drying now, should get it all back together in the next day or so.

It was interesting to learn from this guy...said the Japanese cast is actually better than a lot of American stuff...called it semi-malleable cast as it will give a little more than other cast.  In this case 1/8" was too much so...crack :p

dt75flh

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Re: weld it or replace it?
« Reply #11 on: Oct 08, 2015, 04:51:43 PM »
Sounds like a good deal, will probably last the life of the truck now..

hytenor [OP]

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Re: weld it or replace it?
« Reply #12 on: Oct 12, 2015, 11:02:29 AM »
Sounds like a good deal, will probably last the life of the truck now..

more likely...longer :p

 
 
 
 
 

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