THE PORTAL HUB - Pinzgauers, Haflingers, Volvo 303s and more!

Thanks Jim. I was waiting for this "tough love" version. As much as I didn't want to admit it to myself , as soon as I saw the puddle of gear oil on the garage floor I had a sinking feeling that my case was probably cracked. Facts being what they are, it's a sucky failure and it's gonna cost me time and money.
But heck, if I wanted it easy and cheap, I'd ride a bicycle....lol
Again, I appreciate the info and will definately consult your posted info to assist in my repair.

So, with the assistance of my Brother in law, we got the front end out. It was an adventure, but a relief upon completion. Dug into the diff case, and to my relief, it's all there, intact and in nice shape. The bearings are smooth, gears aren't missing any teeth and the case is not cracked. As suspected, the cheese head bolt that holds the spider gears together had fractured in it's shaft and worked it's way out until finally the big "bang" as it contacted with the spinning gears.

You can still see the threaded end in place, so looks like I'll need to drive the gears out with a pin punch and get the bolt end removed. Hopefully then just a matter of putting it all back together with a new bolt and away we go.

Any observations or advice is welcome of course!

P.S. I know I need a new split boot...lol

stiffler4444 wrote: P.S. I know I need a new split boot...lol

Forget split boot! Get yourself a solid one...since it is apart and all.

I'd still have to pull the axle drive....guess I might as well learn as I go....it would match the other side....

I'm not sure I'd go with a solid boot. Solid boots are definitely nicer than split boots. But unless you've got the wheel drive off already for some other reason, it's a lot of work to go through for not a huge difference in performance, IMHO.

Yeah, the diff. is out of the truck, but that's not exactly "apart and all" as far as boots go. A split boot can be installed now with relative ease, while installing a solid boot requires some further "apart and all" of the wheel drive. Frankly, I'd rather remove a wheel drive with the differential still attached to the truck so the dang thing will stand still.

Which leads me around to the reason I was going to reply in the first place: What did you use to support the differential while you removed it from the truck? I've removed my rear axles on my 712, but there you just roll the rear axles out on their own tires. I've never had the misfortune to need to remove a single axle yet. How did you support it, and how difficult was it?

I used a heavy duty floor jack to pull it out. Kept the stress off the input shaft and rolls easily. The only tricky part was removing the springs first, but a little bit of jacking on each side respectively unloaded the springs enough to remove safely.

Tx Dave

Got some parts on the way from Scott, figured it's a good time to update my front shocks too

undysworld wrote:I'm not sure I'd go with a solid boot. Solid boots are definitely nicer than split boots. But unless you've got the wheel drive off already for some other reason, it's a lot of work to go through for not a huge difference in performance, IMHO.

Yeah, the diff. is out of the truck, but that's not exactly "apart and all" as far as boots go. A split boot can be installed now with relative ease, while installing a solid boot requires some further "apart and all" of the wheel drive. Frankly, I'd rather remove a wheel drive with the differential still attached to the truck so the dang thing will stand still.

Which leads me around to the reason I was going to reply in the first place: What did you use to support the differential while you removed it from the truck? I've removed my rear axles on my 712, but there you just roll the rear axles out on their own tires. I've never had the misfortune to need to remove a single axle yet. How did you support it, and how difficult was it?

I've decided to go with the split boot, as per your point about the wheel drive being easier to deal with while it's "in" the truck. Maybe next time I'll do the solid boot(s), as I presently have 2 solid and 2 split....I don't really feel like any additional work after pulling that front end out!

Soooooo......got all my required parts from E.I. and S.A.V. today. Split boot, shocks, a couple of ignition keys, some brake/tail lights and..........

the real culprit of all my woes......the 10mx70 exection 1 bolt. Well, I ordered 2 just because.....

Anyways, thanks to the suppliers for the quick shipping and special thanks to Scott at E.I. for throwing in a couple of items I needed for no charge. That's impressive these days!

Just got this pic from the Bro in law at the garage. Old broken bolt threads are removed with delicate care. Looks like diff reassembly will take place tonight. Things are moving along rather smoothly...........so far

New 10m70 bolt installed...with a healthy dose of permanent thread lock..

Take lots of pics!!

berger wrote:Take lots of pics!!

Pretty much trying to take a pic at every step of reassembly. Will post up after each major piece. The pics will be of great value for others who need to disaggregate the front end/diffs. I hope not to do it again for a while.....

tx Dave

Got the gears back into the case (bottom half anyway). Will be double checking everything tonight then hopefully bolting all back together ahead of the impending reassembly process. Getting excited to have front wheels again.....

Good pic of the o-ring.

I'm going to have to remove the aluminum ring the boots slips over to replace a few things, but mine is really on there tight. With the case open I am sure it is easy, but was yours stuck on, or did you need to remove it?