H. Differential Bracket Repair (Minor Cracks)

(Minor Cracks Less than 3/8 inch (9.5 mm)

1. Remove the battery from the battery tray and store it a safe distance from the welding area.

2. Disconnect and remove the left half shaft from the wheel flange.

3. Use a cut off wheel or die grinder to remove only the cracked portion of the weld from the differential support bracket (Figure 15).

4. Drill a 1/8" inch (3 mm) hole at the end of each crack.

5. Using a small hammer, reform metal around cracks to minimize gaps.

6. Weld completely around the differential bracket, cracks and over existing welds.

7. Clean all weld areas and apply zinc rich primer (P/N CAAM9987) to all new welds and bare metal.

8. After the zinc rich primer is dry, apply black spray paint (P/N CAAM9988) to rich primer applied in Step 7.

9. Continue with Section "K - Install Fuel Tank - Roadster" or Section "L - Install Fuel Tank - Coupe"