How to Remove a Welded Differential Cap

A rear differential is a gear box that takes the power from the transmission and driveshaft and transfers it to the rear wheels, which turn the wheels powering the vehicle. On certain differentials, especially front-loading differentials like the Ford nine-inch, the cover, or "hump," on the rear of the differential is welded to the differential housing. As these covers are welded to the differential housing, cover removal measures require a bit of "elbow grease," as welds are designed to permanently mount the cover to the housing.

Instructions

1

Set the differential up for grinding, placing the welded cover upward for easy access.

2

Mount an aluminum oxide grinding wheel to the hand-held grinder. Place the wheel on the grinding pad and tighten the nut snugly with an adjustable wrench.

3

Don safety gear. Due to the dangers of rotating grinding wheels, including abrasion and flying sparks and pieces of metal, be sure to wear work gloves, safety goggles and a long-sleeved shirt.

4

Turn the grinder on and begin grinding. Pick a starting location on the weld and, using the outer edge of the wheel, work along the weld. Be careful not to over-grind the cover itself; try to keep the grinding wheel on the weld itself. Continue grinding until the weld is ground down and the cover can be removed.