RTH: Part-Time Spool Install - OK to remove Front Side Gear from Pinion?

[Dirt J]

I'm planning to re-install the gear stacks tonight and get it all sealed back up to measure for shims.

For the spool, I pulled all of the spider/pinion gears from between the new spool and low gear/shaft (pinion shaft, pinion gears, pin, and front and rear side gears -- see pic).

After re-watching my resource videos on Youtube, it appears they only remove the items marked in red and leave the front side gear. I think the new plastic spacer on the back of the new spool is designed to hold that gear in. But I'm almost certain I saw one that removed the front side gear and corresponding thrust washer.

Regardless, I don't any function that gear would serve without the rest of the pinion in there. Thoughts?

@cruiseroutfit

 

[Dirt J]

I knew the answer was in here somewhere:

It is needed to support the front output shaft.

You can see the shaft inside the front spider gear in the pic below. I didn't realize this since my front extension housing was already removed when I got to this step.



Fortunately this will just require removing those 12 bolts and re-inserting the thrust washer and gear. No press work.

 

[Dirt J]

Wasn't quite as easy as I had hoped. Removed the 12 bolts, but the spool is a very tight fit inside the low gear. Didn't want to just pop/pull out like the original rear portion of the center diff.

I tried tapping all around the outer edge and the hub portion of the spool near the bearing with a brass drift, but it wouldn't budge.

I also tried driving out the spool from inside the shaft, but apparently the only lip to catch on is the plastic bushing/spacer on the back of the spool...which of course I shear a piece off of.

So I'll be in touch with @cruiseroutfit for a replacement plastic bushing.

Next plan of attack is heat on the low gear to tried to get the spool to release. Also taking other suggestions.