F-250 rear dana 60

[Chris390]

I was wondering if I should have if it welded where the axle shaft and carrier meet because there is a crack down the center of the original weld is? Will it harm anything?

[eggman918]

could you post a pic?
When I bought my Highboy 25 years ago the D44 front in it was cracked from the ranch hands that had flogged it in it's first life,I was a machinist at a repair shop at the time.
We pulled it and disassembled it to weld the housing that worked fine while we were at it we welded the joint where tube met housing and within a year the weld between tube and housing cracked it never leaked and was still going strong 20+ years later when i replaced it with a disc D44.
The shop where I did this was very experienced with repairing large cast items and we had a large oven to preheat/cool it properly so if it was gonna work it should have with the process we used.
It cracked where weld met the cast it cracked all the way around in a perfectly straight line.
The tubed in a dana axle are pressed in to housing and secured with plug welds that in ~3/4" holes in the housing so there should be a visible joint where tube meets housing.On the D44 I,m running now I had a bit of gear lube seepage at the joint so when it was apart for overhaul I cleaned the joint real well and applied lock tite the type that is for assembled fasteners to the seams and so far ~25,000 miles it has yet to leak any.