Hey folks,

Well, eating it today. Yesterday I was out trying to R&R a leaking rear axle seal on my wife's 2001 Expedition (as I did 2+ years ago); everything was going fine until the set screw/bolt holding the Pinion gear axle in place SNAPPED OFF IN THE DIFF HOUSING.

I started to try to drill out the broken bolt (sure), but couldn't get the right angle on the hole from under the truck, plus the broken bolt's a Grade 8 I think so I doubt I'll be able to drill it without the bit walking into the housing.

So, now that the tears have stopped, what's the correct way to fix this? I'll pull the whole axle to get at this if I have to, but would rather do this the smart way before disassembling the whole back end of the truck.

Thanks for your help.

John

 

Are you talking about the pinion pin bolt?

 

In the past I've had luck with a little heat and a left hand drill bit.

 

Diverdom and MisterCMK,

Yes, I'm talking about the pinion pin bolt, the bolt that holds the pinion axle shaft in position. The torque spec on the thing's small (22 ft-lb?) and I know I used a torque wrench when I put it back together last time; can't understand how a relatively non-stressed bolt could snap like a carrot but as we all know, it happens.

I'll try the left-handed drill bit while playing a propane flame on the housing. On the off chance this doesn't work (just sayin'...), what'd be alternatives? Cut/torch the pinion axle and R&R the pinion gears with a new axle? Pull the whole axle housing and do something else where I have better clearance/access? I can't be the only idiot this's happened to.

Thanks for your help.

John

 

Go to a bone yard (or eBay) and get another carrier.
http://www.ebay.com/itm/181367942620?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT

 

RockAuto has new carriers for about 175 bucks if it's the 9.75" one.

 

Cut the pinion pin with a torch

 

Thanks to all for the advise here. I'm torn about pulling the entire axle out because then I'll have to get the rear aligned and who knows what that'll be.

- The best option is probably get/drill the bolt out without buggering up the threads. I'm going to get some left-handed bits and give it a try.
- If that doesn't work, I'm torn between pulling the whole axle so I can get at it better, or cutting the pinion axle with a torch.
- If I cut the pinion axle, get the axles out, R&R the seals, then find another pinion axle to replace the one I cut. Still gotta get the broken bolt out of there, though, but I can at least pull the whole pumpkin out, get at that broken bolt.
- Bite the bullet, pull the axle and do the bolt removal work with the axle on end suspended by the chain hoist so I can get at it.
- Last is do all that but bag it, pull the carrier, replace it with a new one ($175) or a bone yard one. Either way I'm into a dial guage, all the shims you need to get things right and some time on the learning curve. At least the axle's out at that point and it's right in front of me in the garage. I can put my 20 T press to work, too.

We'll see...

Thanks again for the help.

John

 

Just making sure here...you know the threads are only up near the bolt head and not at the tip of the bolt, right?

 

Good point, probably ought to get the new bolt and compare the thresed depth with what I have where it broke off. If what was left in the hole wasn't threaded, or threaded very little, getting it out should be less of a problem. I'm thinking I still have to drill into it and get a grab some way, though.

 

I believe this is the bolt:

 

The ones that broke on me had very little thread left. I think the bolts were broken already before I put the wrench on them.

 

Man, if that's the guy I don't think there's much of any threads left in there. I'll try to pick one up today.

 

I know I'm bringing up an old thread but it's with good information!

I found the pinion shaft bolt broken when I tore into my '99 Mountaineer's 8.8 rear end a couple of years ago. I tried several solutions from online experts and then I found this:

KIT INFORMATION

Buy one BEFORE you need it. Even if you don't need it when you open up your pumpkin, one of your buddies will and you'll be the HERO! It's not a use it once and throw it away kit, you can use it and still save the day for your buddy.

Just sayin' . . .