Diff Removal - Help Required

[mk1fan]

So it's been a sh*** weekend. Had 10 jobs to do. Got 2 done.

How does the diff come out? Do I need to remove the front mount cradle? I just can't see how it comes out.




If the cradle does need to come off then how does the hive suggest I deal with the recessed lower bolt?



I'll update the rebuild thread separately. Truth be told this weekend has tried my patience.

[Alan461]

I found the steel bolts had ceased in to the ally diff case, took a lot of effort to get them free then the diff dropped out of the diff carrier easily

Eta looking at the photos might be you need to drill the heads off the bolts. Enjoy

Edited by Alan461 on Sunday 10th May 21:22

[mk1fan]

I've got the three 'exposed' nuts of the cradle out easily and they are just holding the cradle at the moment.

The 'recessed' fourth bolt is surrounded by and packed in place with solid rust. Any ideas how to get it out?

I could take a cutting disc to it as I have a replacement cradle as a last resort.

[Alan461]

Didn't drop the cradle, can't help

[glenrobbo]

In my garage I have a spare diff which was removed from the cradle using a cutting disc. The bolt threaded portions are still seized into the ally casing.
I haven't tried to extract them yet. Obviously the last owner had the same steel/ally dissimilar metal corrosion problem. I'm not sure what access is like with the body in place, but cutting them may be your best option Stewart.
Have you tried a little bit of heat &/or freeze spray? Plus a bloody good crack with a 2lb persuader & a blunt bit of round bar?

[mk1fan]

It's hanging down below the chassis at the moment.

Might try welding a nut on. Just need a welder.

The other bolts weren't stuck and the threads were clean. It's the frame thats rusted.

[glenrobbo]

Lots of PlusGas & an ice pick to clear away the restricting corrosion?
And may be grind a socket a bit slimmer?

[Kitchski]

You can remove the diff and the cradle in one. Remove the rear mount completely, then remove the top mounts completely so you've just got it supported on wood or something.
Then with a bit of twisting and turning, it will come out. I think I went all the way backwards with it, lifting the back and dropping the nose slightly as I went. Then I rotated the whole thing by 90degress and the nose drops out underneath.

It is easier to do it without the cradle though. Definitely put them back in separately, otherwise you'll scratch all your nice new paint!