Good Evening,

well the old ball ball joints are out, new ones are in and now I'm working on removing gear assembly so I can change the inner axle seals. I've been trying to get it out. It haven't had much luck. I've loosened the cap bolts, prayed, pulled, hit, and still no luck. The only thing I've been successful at is screwing up the first few threads of the bolt holes for the passenger side cap. Tomorrow I'll be getting a tap and chasing the threads to clean them up. Hope I haven't screwed it up too bad.

Anybody have suggestions on how to get the gear assembly out?

thanks,
Jeff

 

Got a picture? I've got a 2WD, so I'm not totally familiar with the 4WD hardware...

 

If it is your first time pulling a diff, it really helps to use a spreader. The diff is a fairly tight fit between the shims and a spreader gives it a few thousandths of wiggle room. Makes the job a lot easier. I highly recommend the differential book from Randy's worldwide. It will answer almost everything you need to know. Also, you need to remove the inner axles before you can remove the diff.

BTW, how did you mess up the threads?

https://www.ringpinion.com/technicalhelp/DiffBook.aspx

 

The threads got messed up because I was looking through the window in my stomach when I tried to get it out the first time. I loosened the caps and then I thought I secured them with about 10 threads deep, well it was more like 1-3 threads deep. When I tried to pry out the case my bar was on the cap instead of the case and it caused me to screw the threads up. I'm going to get a tap and chase the threads to see if that will straighten them out if not then I will drill out the first couple of threads and use the tap to get them started correctly.

Thanks,
Jeff

 

I can get you a another Dana 50 pretty cheap.

 

Well if I can't fix the threads what are you considering as cheap? Fully assembled or stripped?

thanks
jeff

 

Fully assembled with leafs if you want them. I think I can get you one for around $200-300.

 

Ok, finally got the carrier out and stuck it right into the freezer. Tomorrow I'll replace the seals and work on the threads. Hopefully it will be reassembled tomorrow evening as a 4x4 and not a 2 wheel drive.

Anybody know the torque specs for the carrier caps?

Jeff

 

Ok, finally got the damn thing finished.

I was able to fix the bolt threads by drilling out the first thread or two then I used a tap to chase the threads to correct the problem. I used a magnet to get all shavings out of the housing.










I put the gear assembly in the freezer last night. After I was ready to install the gears I pulled it out and stuck it in. Took some encouragement using a 2x4 and a rawhide mallet but it finally seated. Torqued the cap bolts down to 80 ft lbs. I did install new inner axle seals before I put the carrier in. It is white because of the frost. After it thaws I cleaned up all the water drippings before putting the cover back on.




Added 2 quarts of this to the front axle for lubrication

I installed new front axle putter seals too. They were a pain to get on, had to pound the heck out of them. I used the bearing assembly to push the seals the final bit.




I want to thank NicMike for loaning me the special tools needed to make this job much easier.




Glad this job is over, can't wait to see how it drives with all this new tight fittings.




Jeff