Diff Ear/Brace Elongation - solution ?

[stuartgb100]

The holes in the diff brace ears on my aluminium casing are elongated.

Have done an archive search but can see little info. Has anyone effected a successful repair/improvement?

Have a few ideas, but if there's a workable solution, I'd prefer that.

Regards,
Stuart.

[patrics]

Stuart

If you are talking about the lower ears, then I just had mine welded up and re-machined using an end mill cutter.
This left a square shouldered recess to tightly fit the tie rod bush.

Regards
Steve

[Lincoln62]

I think a steel or bronze bush would be a good idea provided there is enough meat left in the alloy for strength. You would never suffer from elongated holes again.

Pete
66S2

[stuartgb100]

Thanks for the replies.

I've had a closer look at both the removed and the (to be) replaced diffs -------------- both have worn ears.

To be clear, I'm talking of the lower ears through which the tie bars locate.

With the diff off the car, I've dry-fitted the tie bar through the ear, with correct washers and rubber bushes, and tightened as much as possible.

The result is that the tie bar flaps around in the ear and is no way secure. So I can see how further wear will inevitably occur.

The "meat" in the ear is approx a quarter inch. Obviously the un-threaded shank of the tie rod is stopping full tightening.

Any thoughts please ?

Regards,
Stuart.