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Old 08-19-2016, 08:49 PM #1
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Question 97 Ltd 4wd no e-locker rear diff 3rd Member stuck on axle housing; Broken diff stud.
After 19 years and 292K miles the rear diff 3rd member is shot - I bought a replacement 3rd member from a salvage yard.

I have the drive shaft off the 3rd member and rear wheels and axles are out.

All 10 rear diff 12 mm nuts have been removed.

What is the best way to break it loose? Pretty sure only the factory RTV is holding it on. I have something under it to catch it.

Also, any tips for removing and replacing broken rear diff stud? I snapped one off.

Thanks for your help...
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Last edited by azcat90; 08-23-2016 at 07:49 AM.
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Old 08-20-2016, 02:48 PM #2
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Heat?
What would happen if I used a plumbers torch to heat up the rtv seam?
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Old 08-20-2016, 03:18 PM #3
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Heat and a big fat hammer are your friends here.
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Old 08-20-2016, 03:42 PM #4
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Quote:
Originally Posted by gamefreakgc View Post
Heat and a big fat hammer are your friends here.
Bleh its already a sauna out here... I shouldn't complain - Pittsburgh ain't Mississippi...

Thanks...

P.S. I saw a good safety tip eariler on a Ford Bronco forum - put 3-4 nuts back on the diff loose to stop it from falling on you when it breaks free:

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Last edited by azcat90; 08-20-2016 at 03:59 PM.
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Old 08-20-2016, 05:37 PM #5
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make sure the axles are pulled out far enough or they'll hold onto the 3rd member.

stud, vice grips if you can get them on...heat and pb blaster.

good luck!
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Old 08-20-2016, 07:25 PM #6
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Quote:
Originally Posted by soupkitchen View Post
make sure the axles are pulled out far enough or they'll hold onto the 3rd member.!
They are standing up in my garage...
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Old 08-20-2016, 08:19 PM #7
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Quote:
Originally Posted by azcat90 View Post
They are standing up in my garage...
gotcha....I guess you can get a super tiny flathead screw driver, tap it between one spot then get one a little bigger and work it around the seal. I had 190k when I replaced mine and came apart pretty easily...even the one I pulled from the yard wasn't difficult.
Obviously be careful not to score the housing when prying. Good luck man.
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Old 08-22-2016, 11:07 AM #8
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Success - the perfect tool came with the vehicle...
Used the jack to pry it open a crack and then used screwdriver, chisels, pry bars - finally came out...



Just give me 3 mm - that's all I need...



OUT!

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Old 08-22-2016, 11:09 AM #9
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I scored
Quote:
Originally Posted by soupkitchen View Post
Obviously be careful not to score the housing when prying. Good luck man.
Hopefully the RTV will do its job...
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Old 08-22-2016, 11:13 AM #10
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Black and Decker 20V cordless drill $68 at WalMart
Quote:
Originally Posted by azcat90 View Post
Any tips for removing and replacing broken rear diff stud? I snapped one off...
I used my cordless 20V impact driver ran a nut down as far as it would go and then reversed it - came right out...

Ace Hardware had 8 X 38 mm 1.25 pitch automotive studs for a buck each...
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Last edited by azcat90; 08-23-2016 at 06:27 PM.
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Old 08-22-2016, 12:53 PM #11
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...and my diff is a 410, not a 430... ha ha ha - they sent me a 430 - I'm going to go inside and finish all the beer in the fridge.
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Last edited by azcat90; 08-23-2016 at 07:50 AM.
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Old 08-22-2016, 02:58 PM #12
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Quote:
Originally Posted by azcat90 View Post
...and my diff is a 410, not a 430... ha ha ha - Junkyard sent me a 430 - I'm going to go inside and finish all the beer in the fridge.
Did it happen to come with an e-locker?
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Old 08-23-2016, 07:48 AM #13
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Nope
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Originally Posted by Toy2play View Post
Did it happen to come with an e-locker?
No e-locker...
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Old 08-23-2016, 04:36 PM #14
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Ordered a 410
410 should be here Monday...
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Old 08-24-2016, 08:01 PM #15
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Quote:
Originally Posted by azcat90 View Post
Hopefully the RTV will do its job...
i used the oem gasket and sealer..no leaks. I'd say you'll be good.

Good thinking with the bottle jack!
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