Real Time Help Req'd: c-clip removal

[gbcruiser]

Trying to get the rear axle c-clips off to throw my Aussie locker in...what's the procedure for removing the c-clips? Basically just pry them off with a flathead screwdriver, or use needle-nose pliers?

EDIT: C-clips are good to go; now unable to get the pinion shaft to slide back in with everything assembled. With the c-clips installed, the spacers won't seem to slide apart far enough to let the pinion shaft slide in.

 

[RredFJ40]

Remove the center pin, push axles inboard, c-clip should slide out, no tools needed.

Make sure you carefully remove the center-pin set screw, I wasn't too careful, busted it and had to take the carrier to a machine shop.

 

[gbcruiser]

Thanks I'll try that right now...

 

[Kavik]

Magnetic screwdriver?

 

[CruisinFJ60]

you cant pry them out....

do like RredFJ40 said take out 12mm bolt in carrier that goes through the center pin. the centerpin will then pretty much drop right out, next push the axles in (easiest to do with tires off since no weight) c-clip will (should) pretty much just drop right out. remove 2 spider gears and theyre washers they ride on and make some nice paper weights with them. then removes side gears and the 2 washers with those (keep the 2 washers off of side gears they will gon on with the new side gears supplied with the rest of the aussie). put in new aussie side gears (with your old washers!) slide in the left (i think for the rear) aussie half (helps with some bearing grease on it to hold it all in place) then the right side (hopefully you already have the pins in the 2 small halfs if not pull em out and put em in) then put in your 4 springs and then reinstall your center pin and your 12mm bolt and your done.

hope that helps if you get stuck again.

oh yea dont forget to add your favorite gear lube back in when your done.

 

[gbcruiser]

OK, got everything out and about 90% reassembled. C-clips are both back on, and (hopefully) snapped into place. No vision verification on the pass side as I can't see in the gap, but it seemed to slide on and the axle doesn't pull out.

Next step is to install the 4 ping springs (which seems easy enough) and then the pinion shaft. Problem: the pinion shaft doesn't fit back in between the Aussie locker spacers--an I can't seem to slide it in no matter what I try.

Any ideas?

 

[Ducks]

Use a bent hanger to push the spacers onto the sides. If you put grease on everything they should just stick there.

EDIT: Did you do the measuring part before the assembly?

 

[RredFJ40]

give a good tug on both drums/tires to pull the axles out, get your springs in there then try the center pin, try cramming a screw driver in there to force the halves apart. Otherwise you might need thinner thrust washers behind the side gears.

 

[CruisinFJ60]

axles are prolly not all the way out of the way or one of the 2 middle teeth looking peices has fallen kinda sideways. center pin should slide right back in w/o any issues. no need to change thrust washers (2 big flat side washers)

 

[gbcruiser]

No amount of axle/wheel pulling and pounding, and screw-driver prying, will make enough space for the @#$@ pinion to slide in...any other tricks I can try before I rip everything out and order some thinner washers?

Things were going smoothly up to now....everything together, springs and pins in place, tolerances near perfect. It always has to be the last thing that gets ya...

 

[Ducks]

I guess I don't understand. If you put it together and measured the tolerances for the pinion shaft with your current thrust washers, why are you now having a problem putting it all together. What measurement did you get?

 

[gbcruiser]

Good point...the first measurement was .016 between the pinion and the spacers. With everything assembled but the pinion, the second measurement is .148 (.145-.160 is spec). But for whatever reason the inner spacers won't slide far enough apart to let the pinion slide in.

I've hammered on the wheels to try and pull them out, but they're out as much as they're going to go. Of course there's a chance I'm inept and can't slide the spacers apart with a screwdriver deftly enough, but after 2+ hours of trying, I don't think that's the problem either.

 

[Ducks]

Wow, that sucks. Well, have a or or ...

I can't really think of anything. Did the second c-clip go all the way on?

 

[gbcruiser]

I think so - I couldn't actually see it go on in that narrow space but it slid in and then sort of fell into place, and after that the axle wouldn't pull out, so it seems locked.

I'm going to get out there now with something larger and meaner to pry with. Maybe I'll be able to work the spacers out another 2mm on both sides. That's the only way the pinion will slide in.

Quick update: After creating a custom tool out of a paint roller, I was able to pry the halves apart and get the locker installed. Thanks for all the help and advice!!