[6pack] Rear differential parts question

[Robert Lang]

Hi,

If your diff is leaking, take two minutes to make sure that the vent is 
not blocked. A lot of times, the vent area gets caked with "stuff" and the 
pumpkin cannot vent. The pressure builds and oil leaks _everywhere it 
can_. Diffs run H-O-T.

If the vent is not caked, then you should replace the stub axle seals and 
while you have the unit out, replace the front seal (aka the pinion seal). 
Also, while it's out, drill out the bottom of the case for a 1/8 or 1/4 
NPT drain plug so you can drain the oil w/o having to remove the diff.

If you crack the case open, you'll need the rear cover gasket too.

There's no gasket between the axle stubs and the case.

Note: the axle seals are a Royal PITA to do. The axles stub to drive 
flange is a taper joint with key. These things pretty much weld themselves 
together in some cases and they will not come apart except with Great 
Effort. Do do this "right", you need a special tool OR you need to 
fabricate a plate (1/2 mild steel, min thickness). Bolt the flange to the 
plate with grade 8 bolts and torque them. Then place the whole thing in a 
press (20 - 30 tonne) and start pumping. Once you get 20 tonne or so, try 
"shocking" the joint with a hammer. If no go, pump it up some more and 
repeat.

Some folks use heat, if you do, don't use a lot or you wreck the temper of 
the axle - you DO NOT want to do that.

Note that in some cases you get the parts to separate, but if you crack 
test the axle stub or the flange you will find that the parts are junk. 
But you should def. crack test while it's apart.

Also note that some early cars use a dinky 1/4" key. These are not 
suitable for heavy usage. The later ones are 3/8" keys. You want those.

This is really a job for a pro or someone that's done the job before. It's 
really easy to wreck the flange, the axle, the sealing flange or the Whole 
Shebang.

There are ways to change the seal w/o taking the axle/glange apart, but I 
do not recommend doing that as the result is an axle stub that will pull 
out if the outer axle separates from the car.

Like I said - this is a job for a pro. A pro with the proper tools.

rml
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