Replacing Differential Housing Gaskets

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I guess the only question I still have is what I have to disconnect to remove the axel shafts. I’ve seen different explanations and I don’t know if my ARB is the same as the one Project Wrong Way installed since it’s ~20 years old. I’ll know better when I open it up. Working on it now.

Same as OEM. Remove pin and block, push in the axles to remove C clips and axles will pull out.
 
Same as OEM. Remove pin and block, push in the axles to remove C clips and axles will pull out.


It looks like you remove the rounded hex screw below the tubing, and then punch out the pin and remove the block. Sound right?

Note the crimped copper tube where it come up from the locker. That can’t be good! I’ve always thought there was something funky with this locker install.


IMG_5188.jpeg
 
A telescoping magnet is great for sliding that pin out.
I’m not sure what you mean.

I pulled the rounded hex screw, and it’s only about a half inch long. Not long enough to hold the center pin. So what gives? What do you need to do to get the Center Pin out?

IMG_5191.jpeg
 
I’m not sure what you mean.

I pulled the rounded hex screw, and it’s only about a half inch long. Not long enough to hold the center pin. So what gives? What do you need to do to get the Center Pin out?

View attachment 3473772

And there it is…. A hollow pin you dig out with a drill bit. The hex screw acts to hold/retain the pin. Impossible to see without a small mirror.
IMG_5192.jpeg
 
Please whatever you do - don’t skip the cork gasket. Rtv is a lazy way to fix the leak and is a pain in the ass to service when you need to do any work with removing axles.

Removing the cover results in hammering in chisels and beating up the mating surfaces. It’s a joke, please do it correctly and torque the cover evenly with torque wrench. It will not leak if done correctly.
 
Please whatever you do - don’t skip the cork gasket. Rtv is a lazy way to fix the leak and is a pain in the ass to service when you need to do any work with removing axles.

Removing the cover results in hammering in chisels and beating up the mating surfaces. It’s a joke, please do it correctly and torque the cover evenly with torque wrench. It will not leak if done correctly.
Do you use RTV on the Cork gasket?
 
BLOWN AWAY BY AXLE SHAFTS:

I pulled the axle shafts, and was shocked by the discoloration near the splines and the bearings. I’m assuming it’s from overheating at one time. The splines look decent and the bearing surfaces are smooth. The Diff/Locker looks great. I’m guessing this happened before I got it. Should I be concerned? What is the availability /affordability of replacement shafts?
 
Do you use RTV on the Cork gasket?
No, torque in x pattern gradually increasing until torque spec is reached. Then do one final Check that each fastener ‘clicks’ immediately once pressure is applied to handle - Trevor at until all match.

This applies to any cork gasket.
 
And there it is…. A hollow pin you dig out with a drill bit. The hex screw acts to hold/retain the pin. Impossible to see without a small mirror.View attachment 3473832
Isn’t there a couple of pins around 1” in diameter that took the place of the original pinion pin that holds the axle spacer block? A magnet will help you get them out since you can’t just push it out from the other end.
 
BLOWN AWAY BY AXLE SHAFTS:

I pulled the axle shafts, and was shocked by the discoloration near the splines and the bearings. I’m assuming it’s from overheating at one time. The splines look decent and the bearing surfaces are smooth. The Diff/Locker looks great. I’m guessing this happened before I got it. Should I be concerned? What is the availability /affordability of replacement shafts?
Throw some pictures up. It’s probably just the heat treatment applied in those areas.
 
Isn’t there a couple of pins around 1” in diameter that took the place of the original pinion pin that holds the axle spacer block? A magnet will help you get them out since you can’t just push it out from the other end.
Just one large center pin. You can literally push out by spinning the hub and pulling it out. Then you take out the block.
 
So, if I pull the axel shafts, can I pull the carrier/pumpkin intact without disassembling, and then put the pumpkin back after replacing the gasket and reinsert the axel shafts?
Unless you have a full floating rear there are C-clips holding the axle shafts in the differential. The shafts will not come out until they are removed.

Everything is accessible once you remove the rear cover that needs to be removed so that you can remove the axles.
 

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