locker re-install help, crosspin stuck

[FJ502]

I am typing this with greasy, sweaty, bloody fingers....

so I am tearing my 3rd apart again to re-install the proper thrust washers in my ez-locker.

I had to shave my crosspin down the last time to get it in (another reason I am re-doing it with a new crosspin)

Now my old one is stuck, surprise! I can push it back about 1.5" with a BFH and a drift but the worm gear and housing stop me from pounding it all the way out.

How do I proceed?

thank you.

 

[snowboardonsnow]

Pictures? I am having a hard time understanding whats going on. you took out the lock bolt I presume, can you rotate the carrier so it will clear the worm gear?

I know how you feel greasy hands and needing to type to ask a Q sucks!

 

[FJ502]

So yeah, I forced it through and now it's up against the back and the dif cannot rotate at all. It's stuck, what do I do?

 

[Pin_Head]

1) beat on it with a bigger hammer.
2) Take the carrier out. Mark the positions of the side adjusters so you get it back in the same position.

 

[FJ502]

How do I get the carrier out without pulling the c clips and pulling the axles out?

 

[snowboardonsnow]

eeak! can you pry it back in a little? I take it the thrust washers you had in there where too thick?

Best bet is to get it back in a little and get her turned. I can't remember is the cross pin solid? you may have to drill it and use a slide hammer to pull it back out a little or carefully cut it with a sawsal or drill a hole beat it through and weld it up... lets hope it doesn't come to that.

Anyway to get a screw driver in there tap it in to relieve some of the pressure on it and shimmy it back in?

 

[snowboardonsnow]

also are the "teeth" on the left side of the locker engaged? hard to tell on the picture, that will loosen it up some. That thing must have been acting like a spool this whole time huh?

 

[Wile E Coyote]

Pry it away from the housing with a cold chisel or pry bar. Touching on a last ditch effort: Try a little heat on the locker and then ice the cross pin. Get it the rest of the way out, and when you reinstall it, grind down the heel of a gear tooth or two instead of grinding the cross pin. Think about thinner thrust washers for round 2.
Last ditch effort part deux:
Put the tires on and turn 'em a bit. Of course use common sense, since it will dig into the housing. It also may force up enough to get the aforementioned cold chisel in there for the real progress.

 

[FJ502]

How do I get the carrier out without pulling the c clips and pulling the axles out?

Is there any way? Or do the c clips have to be removed before the axle shafts or third member will budge?

 

[snowboardonsnow]

There isn't any way the that I can think of, even if you unbolt the carrier it would still be stuck, I just thought of another way though. Drill a small hole say 1/4 or so right on the other side of the housing where the cross pin it stuck hammer it back. Then either weld the small hole shut or tap it and put a bolt with a copper or other sort of seal on it.

 

[60Works]

I'm not that experienced with differentials but if you unbolt the two bearing caps will it allow the axles to come aft far enough to allow you to turn the diff?

Maybe it would be enough to get a wedge under the cross pin so if you tighten the caps back down it will push the pin in?

 

[FJ502]

There isn't any way the that I can think of, even if you unbolt the carrier it would still be stuck, I just thought of another way though. Drill a small hole say 1/4 or so right on the other side of the housing where the cross pin it stuck hammer it back. Then either weld the small hole shut or tap it and put a bolt with a copper or other sort of seal on it.

He he he, that would have been a good idea. I ended up cutting a crosspin size hole in the opposite side and tapping it through. Pics to come.

 

[snowboardonsnow]

hahaha, nice well its all good because I am pretty sure you know your way around a welder

 

[FJ502]

Yeah, I have a Millermatic and I can stack boogers like a 1st grader.