My 94 front diff suddenly has a hole in the bottom of the pumpkin. Looks like a gear inside has broken off somehow and is sticking out a bit. I can and did push it back in with a bit of force, filled it back to the top, and drove it back home - Leaking.

Anyone have experience rebuiding the diff? I don't but I'm gonna repair it myself (I know engines but never had to deal with running gear). I assume that I can weld the pumpkin hole closed once I pull, id, and replace the bad gear. Any tips would be much appreciated. Thanks.

 

Yes, you can repair the diff case. Are you running lockers or are you stock? If not you should be able to rebuild or replace the third member.
Let us know what you find when you open it up.

 

stock running gear pushing 285's (suspect that might have some contribution- they've been on for a few years). No experience weld a pumpkin hole (size of a cashew) but I figure that draining and cleaning out all lube will allow welding without fire - And that way keep it in the drive at home.