97 Ltd 4wd no e-locker rear diff 3rd Member stuck on axle housing; Broken diff stud.

[azcat90]

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...

 

[azcat90]

Heat?

What would happen if I used a plumbers torch to heat up the rtv seam?

 

[gamefreakgc]

Heat and a big fat hammer are your friends here.

 

[azcat90]

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:

 

[soupkitchen]

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!

 

[azcat90]

make sure the axles are pulled out far enough or they'll hold onto the 3rd member.!

They are standing up in my garage...

 

[soupkitchen]

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.

 

[azcat90]

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!

 

[azcat90]

I scored

Obviously be careful not to score the housing when prying. Good luck man.

Hopefully the RTV will do its job...

 

[azcat90]

Black and Decker 20V cordless drill $68 at WalMart

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...

 

[azcat90]

...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.

 

[Toy2play]

...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?

 

[azcat90]

Nope

Did it happen to come with an e-locker?

No e-locker...

 

[azcat90]

Ordered a 410

410 should be here Monday...

 

[soupkitchen]

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!

 

[azcat90]

This may be the end...

So I replaced the diff after having to buy a transmission jack to lift it, dealing with another broken stud due to wrong torque spec. Drove it last night and the noise is still there.

I spent a lot of time effort and energy and am still in the same place I was when I started.

Will probably trade it in for a 2002 Lexus RX 300 this afternoon.

300K miles will not happen.

 

[azcat90]

Goodbye 4Runner

Just saw the last of it. Thanks to everyone on here for the help...

 

[Red Monkey]

It may have been your axle bearings and not the diff making the noise.

 

[azcat90]

Too late...

It may have been your axle bearings and not the diff making the noise.

I didn't want to deal with it anymore...

 

[Scramble]

Sounds like a lot of time & money wasted to not fix the problem. Could have been something simple like the Driveshaft or a u-joint.
Should have done axle bearings & seals since you were into it that far.