| Author | Message | ||
     Craig McLaughlin (Cmclaugh) New Member Username: Cmclaugh Post Number: 25 Registered: 06-2002 |
What are the steps involved in removing a front diff on a D2? How do you get the left and right axle shafts pulled out of the diff so you can drop the 3rd member? Any tips would be most appreciated. | ||
| Dave_lucas (Dave_lucas) Senior Member Username: Dave_lucas Post Number: 335 Registered: 02-2002 |
Craig, I just did both the front and rear last weekend, in my opnion you do not need to remove the axle completly as it states in the directions below, just pull them out enough to clear the 3rd member, also watch out for the ABS lines you will need to be carefull with them. FRONT AXLE REPAIRS Differential - assembly Remove 1. Raise front of vehicle. 2. Remove front road wheels. 3. Drain oil from differential. 4. If same components to be refitted, reference mark propeller shaft and mating components. 5. Remove 4 nuts and bolts securing propeller shaft to differential. Release propeller shaft and tie aside. 6. Remove LH and RH front brake discs. 7. Disconnect each ABS sensor multiplug. 8. Release each harness from brake hose and hose bracket. 9. Remove 4 bolts securing each front wheel hub to front axle. 10. Release wheel hubs from front axle. Remove wheel hubs and drive shafts from front axle. 11. Remove oil seal from axle casing. 12. Remove 10 bolts securing differential to axle casing. Release and remove differential from axle casing. Refit 1. Clean drive shaft oil seal recess, oil seal running surface, wheel hub and axle mating faces. 2. Using a suitable solvent, clean old RTV sealant from differential and axle mating faces. 3. Apply RTV sealant to differential or axle mating face. 4. Apply Loctite 243 to threads of differential securing bolts. 5. Fit differential to axle, fit bolts and tighten to 55 Nm (41 lbf.ft). 6. Position propeller shaft and align reference marks. Fit bolts and tighten to 47 Nm (35 lbf.ft). 7. Lubricate oil seal lip and running surface with clean differential oil. 8. Using LRT-54-012 and LRT-99-003, fit new drive shaft oil seal to axle casing. 9. Apply anti-seize compound to wheel hub and steering knuckle mating faces. 10. Ensure ABS harnesses are located in cut out in steering knuckles. 11. Fit drive shafts in axle casing and align wheel hubs with steering knuckles. Fit wheel hub bolts and tighten to 100 Nm (74 lbf.ft). 12. Connect each ABS sensor multiplug and secure harness bracket and brake hose. 13. Fit front brake discs. 14. Fit front road wheels and tighten nuts to 140 Nm (103 lbf.ft). 15. Remove stand(s) and lower vehicle. 16. Fill differential with oil. | ||
| Craig McLaughlin (Cmclaugh) New Member Username: Cmclaugh Post Number: 26 Registered: 06-2002 |
Thanks for the information Dave! Did you have problems with your diffs or were you just upgrading them? I've got a nasty driveline clonk coming from the front of my 99 D2. I was changing the front diff oil when I noticed it came out gray with silver specs. The drain plug had about a half inch of gray sludge topped with a pile of metal shavings. This isn't normal right? BTW, do you rebuild your own diffs or do you have someone else do it? | ||
| Dave_lucas (Dave_lucas) Senior Member Username: Dave_lucas Post Number: 336 Registered: 02-2002 |
Craig, "Did you have problems with your diffs or were you just upgrading them?" I just swapped them out with 4.10's and Truetrac's, the diffs were working fine. FWIW I did have a small amount of stuff on the drain plug, no chunks just a fine metal silt, but the 90wt looked fine, I expect some wear after 30K and never changing the fluid. "BTW, do you rebuild your own diffs or do you have someone else do it? " I have done my own diffs in the past Dana 44's mostly, but I used some that were already setup this time. |
