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what does it involve to fuse the spider gears on the rearend of an F-250? Is it a smart or stupid thing to do and what does it do to the reliability of the rearend? and suggestions would be apreciated!
This is sometimes called a "Lincoln Locker". It involves welding the spider gears in the differential as a cheap way of locking your axle (as opposed to putting in a Detroit Locker, or ARB locker, etc.).
The only reason doing something like this would make sense is a) you only off-road your truck (welded spider gears are NOT going to work well or last long on the pavement); and b) are a good enough welder to do it right or you'll booger it up from the start and you won't be going anywhere on-road or off.
Frankly, it would be worth the $600 to get a good locker and be done with it. Having said that, I'm sure several guys here can post that they've done it and it's worked fine, but I wouldn't recommend it.
Welding your gears and running a locker are no-how similiar... A spool would be would compare to welding the gears.. As lockers will unlock around corners and keep you streetable, Spools and/or welding your axle to one solid unit will make you unstreatable..