Help please... more issues

[bdegs]

Hey Guys,

I just cracked open the diff on the D60 I took off another truck and put under mine. Looks like the previous owner snapped off the bolt that holds the pinon shaft in. It looks to be broken off just at the threads.

Ideas on the easiest way to get this out???

Also it is a DRW dana60, after I take the hubs/rotors off the shafts should just pull out like a 10 bolt right?

Thanks

Update: I used a punch as was suggested to knock out the pin holding in the pinion shaft. I tried from the ring gear side like the instruction for the lockrite said. I wouldn't budge after an hour of pounding. So I tried from the other side. No budge. Any ideas?

I then decided to pull the carrier and get a better angle but after pulling both axle shafts and bearing caps I can't seem to get the carrier out!

Thanks for any help... again.

I swear I have done this on 10b and 12b many times with no problem, its this 1-ton stuff that is kickin my butt!

 

[Hogback Fabrication]

Hey Guys,

I just cracked open the diff on the D60 I took off another truck and put under mine. Looks like the previous owner snapped off the bolt that holds the pinon shaft in. It looks to be broken off just at the threads.

There is only one nut that holds the pinion shaft in, the pinion itself is threaded. Pics?

Also it is a DRW dana60, after I take the hubs/rotors off the shafts should just pull out like a 10 bolt right?

Thanks

Yep

 

[4X4HIGH]

Sounds like your talking about a front D60 since you said hub/rotors. The cross shaft is held in with a roll pin and not a bolt like rear diffs. Once you have the outers off the axles will just pull out. The only reason to have to remove that roll pin is if you're installing a lunch box locker into that carrier or if you have broken spider/side gears.

I'm assuming this is what you meant.

 

[bdegs]

Sounds like your talking about a front D60 since you said hub/rotors. The cross shaft is held in with a roll pin and not a bolt like rear diffs. Once you have the outers off the axles will just pull out. The only reason to have to remove that roll pin is if you're installing a lunch box locker into that carrier or if you have broken spider/side gears.

I'm assuming this is what you meant.

Your exactly right. I am installing a lockrite. Should I pound the pin toward or away from the ring gear???

 

[4X4HIGH]

If memory serves me right with the carrier out and the ring gear off you can drive the roll pin either direction. There really isn't any good way i know of to remove that roll pin with the carrier still in the axle and the ring gear still on the carrier. There must be some way of doing it though as many people have installed lunch box lockers and i doubt they all pulled the carrier (i could be wrong though).

 

[4X4HIGH]

Ok, it sounds like you have your terminology for the ring and pinion gears backwards.

The small bolt that is broken is the one that holds the cross pin in, right? If that one is broken, I would remove the carrier (make sure to mark which side and orientation for each carrier bearing cap) and then remove the broken bolt. It will be very hard to remove with the carrier in the diff.

There is no broken bolt (he was mistaken), it is a front diff and it uses a roll pin to hold the cross shaft.

 

[Hogback Fabrication]

There is no broken bolt (he was mistaken), it is a front diff and it uses a roll pin to hold the cross shaft.

Haha, I actually deleted that post because I realized that it used a roll pin rather than a bolt like most do.


bdegs, use a punch to drive the roll pin out (I forget which direction, the locker instructions should tell you), then tap the cross pin towards the pinion gear (towards the back of the housing). Turn the carrier 180 degrees and pull the cross pin out, replace the spiders with the locker and then reassemble everything.

 

[4X4HIGH]

Yeah, i copied your post and left my response and when i hit reply i was like WTF he deleted his reply. I figured that you discovered it was a roll pin and not a bolt so that's why you deleted your reply but you weren't quick enough in deleting your post.

 

[bdegs]

Thanks for all the help guys. Guess I freaked out for no reason. I will pull out the punch and hammer and go at it.

 

[bdegs]

Update: I used a punch as was suggested to knock out the pin holding in the pinion shaft. I tried from the ring gear side like the instruction for the lockrite said. I wouldn't budge after an hour of pounding. So I tried from the other side. No budge. Any ideas?

I then decided to pull the carrier and get a better angle but after pulling both axle shafts and bearing caps I can't seem to get the carrier out!

Thanks for any help... again.

I swear I have done this on 10b and 12b many times with no problem, its this 1-ton stuff that is kickin my butt!
__________________

 

[4X4HIGH]

To remove the carrier you might need a couple large pry bars. I would suggest placing the caps back on with the bolts a few threads in so the carrier doesn't shoot across the garage.