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Nothing wrong with being curious. Having welded plenty of diffs as a young man with more 7018 and electricity than money for lockers I can tell you it will work till the welds break (throw some bolts or chunks of ready rod between the gear teeth and weld them in) - or maybe they won't break -...

That still wouldn't do it - the inner gear is free-floating on the splines. You can't weld it since that would make hub service impossible. And if you shave off the spiders where they contact the inner gear/nut retainer then nothing holds the inner gear into the nut. You need a way to delete the...

Exactly. Waste of time to even consider wrecking a bunch of parts by welding all over othem when a tested product is available to do it the right way. The hubs pay for themselves in ~3500 miles just in fuel savings. If you can't afford to do it the right way then these aren't the trucks for you...

So wait - it overheated AND you lost "power" - what does that mean exactly? Full story please.

Your transmission is the Allison MD3070. The 3700SP wasn't introduced into the FMTV till about 2005 or so and always has the WTEC IV controller. All of the transmissions fall under several service bulletins about the C6 clutch thrust bearing failing and bearing parts ending up various places...