I have done what I can to not grab the cutting torch and chop this thing out...

The differential cross pin retaining bolt, has broke in half. I have all the threads, but no pin. The cross pin is snug and I can't move it back and forth with my fingers so it's making this job even harder. I've gotten these out with a magnet or small pick before, but the cross pin always wiggled.

How can I get this out without losing my mind?
I currently have axle out and standing on it's end, hoping gravity would help, but without the cross pin moving freely, it is a little difficult.

 

Uggh, the ultimate taboo of working on an 8.8. The dreaded cross bolt.

Try a little heat from torch to open the clearance a bit? Might get a little messy if you get too hot and the oil catches fire.

 

Yea that is a problem made worse by a cross pin that won't work with ya a little bit.

Short of getting a line on it so as can drill what's left that torch is probably looking pretty good at this point!

Might try tack welding a nut to the end of the cross pin for something to put a wrench on, or short bolt for something to grab. tacking something to it wouldn't hurt the pin and easily removed after the fact.


Being as its up ended have gravity working for you tap on the carrier causing a little bit of vibration maybe persuade whats left of that little pin to fall out? ....yea you probably tried that though!

 

Ya, using a stick welder, put the rod in the hole and touch the broken pin. It should tack itself enough to use the rod to pull it out. Even a MIG gun might work. Worth a try.

 

I feel your pain.

 

Don't torch it. Get a dremel and cut off wheel. Cut edge of pin straight through the bolt. Then you can pull pin and remove carrier. Once the carrier is out you can get the remains of the bolt out easily. You will get into the carrier some. iTS OK!! I have done this. Had it out in 10 minutes. Rear end still in truck today

 

Btw, that bolt is only threaded on the head side. The parts store keep the Dorman brand replacement in stock. If the cross pin has any wear, order a new one. This is the main cause of slack in the differential.(that clang from the rear end when going to drive or reverse)

 

I got a long drill bit and made a drill pilot, now to acquire an easy out and pull the pin out. It's got some pressure on it for some reason.