Front Differential Spanner Lock Tab Replacement

Pulled the front diff to replace the oil pan gasket and also needed to replace the leaky driver side axle shaft seal. Once I removed the seal I found the lock tab broken off. I'd really like to not do a full rebuild of the front diff, or even split the case if I don't have to, but what are my options?

Prior to discovery, 4wd worked fine. I had a humming noise at 10-30mph and no noise at highway speed. I attested this noise to low fluid (did a fluid change and barely any came out, refilled and realized the seal was completely shot and leaked everywhere) but reading a few posts I'm seeing this could be attributed to other issues.

My ethos is typically to do it once and do it right, but for an 04 with 210k miles, I'm not looking to spend a ton- can I just JB Weld the tab back in place?

Welcome to the Forum from NH.

Lots of knowledgeable folks here who freely share their knowledge, experiences, and perspectives. Knowledge is power.

I hope that you will become a participating member in the Forum's discussions.

Pics of the truck, please. If we can't see it, it does not exist.

I cannot personally assist you with your issue, but other members of this Forum much more knowledgeable than me in this area will chime in.

Here's the truck in its current state, along with the adjuster/broken lock tab. Assuming the adjuster has not moved, and therefore the backlash is ok, I can't think of a reason it'd be a problem to JB weld the tab back on since the adjuster isn't suppose to move once set anyway. Of course a subsequent rebuild could be jeopardized, but I can pick up a front diff at the junkyard for $100. Seems like a good risk/reward to jb weld the tab, drive it, and if it makes noise then I know I have to rebuild the diff completely lol.

split the case and change the lock tab correctly. If the carrier bearings are in good shape, reseal and re assemble.

For what it's worth, I have not taken a single 8.2 IFS diff apart that had good carrier bearings. The locking tab is a poor design on these.