HELP! Stubborn rear diff

88Cleve4runner

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Stubborn rear diff - TTORA Forum (link to another site for other info)

I'm having the hardest time getting my rear diff out (97 runner, v6 diff, 8"). Before you guys start laughing... Hear me out. Shafts are pulled, nuts off studs, 2 studs backed out, 2 studs sheared off at the diff not the housing. I've beat on it with a hammer, I've put the bottle jack under it, I've put the bottle jack against a lower link, bent said link while jacking, beat on the flange towards the front of the truck. My next idea is 2x4 laid on the control arms against the diff and extending out from the truck so I can really hit them with a sledge. It's been soaked with PB over and over. I'm pretty sure those are all of my methods. Has anyone else had this problem? I'm 99% sure the diff hasn't been pulled because the PO had it since 98, mechanic did ALL work and maintenance, PO didn't even know what a diff was when I bought it from him. Any ideas guys?!

Update: Somehow I'm able to get separation between the bottom of the diff face and the axle housing. But from about 10 o'clock to about 3 o'clock and up, no separation... Beating 2x4s that touch the diff, rest on the lower link, and extend out a little so I can get a baseball swing are how I got the most separation... Brute force really. I've tried scissor jacking from above the diff (just lifts the body). The only thing I know to keep doing it hitting with the 2x4s and trying to drive chisels in between them. Anybody had this issue before or know what to do?
 
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That's really weird. If you have a little gap between the third and the housing at the bottom, slide a fat cold chisel in there and just pound it in like a wedge. It'll come out.
 
Got a torch? I'm a big fan of heat to help loosen stuff up. I would probably focus the heat around the stud holes in the 3rd to open up the clearances. But I'd do what Kid said first.
 
That's really weird. If you have a little gap between the third and the housing at the bottom, slide a fat cold chisel in there and just pound it in like a wedge. It'll come out.

I've tried that, it only pulls it apart so far before I hit it and nothing happens and still no separation at the top.
 
I've tried that, it only pulls it apart so far before I hit it and nothing happens and still no separation at the top.

When you get to a certain angle, it's going to bind on the studs. Try with the chisel again, and when you get to where it won't come any farther out, shim it with something and take the chisel around the side to try from another angle. Or doublenut the studs and back them all out so they're not in your way.

But if that doesn't work, I'm out of ideas. Once you've removed the nuts from the studs and pulled the axle shafts, there's nothing else that should be holding the third in besides the gasket seal, and you've obviously broken that if you've got separation.
 
Are you sure you're not missing a bolt somewhere??

There's no reason this thing should be that hard to get off the housing. I had mine off numerous times, the hardest being in a storage building with nothing but the 12mm(?) socket and wrench. Still managed to get it off though.

You're using a fawking sledge hammer to try and get it off. There's got to be something else holding the damn thing on. Though don't know how much abuse some gasket stuff would take.

Might just have to buy some from Toyota. If it'll take the abuse of the sledge, I'll coat my fawking house in it for the damn apocalypse........
 
I got it out last night. I still don't fully understand what was holding it in. Screw driver shafts weren't thick enough to keep pushing the diff out when I would pound them in so I got 2 really thick chisels. The chisels and still pounding on the breaker bar that was against the flange were the 2 things that got it out finally.

In conclusion... It's out!!!!!! But I still have no idea what held it in so tight either?
 
I got it out last night. I still don't fully understand what was holding it in. Screw driver shafts weren't thick enough to keep pushing the diff out when I would pound them in so I got 2 really thick chisels. The chisels and still pounding on the breaker bar that was against the flange were the 2 things that got it out finally.

In conclusion... It's out!!!!!! But I still have no idea what held it in so tight either?

Glad you got it out. I'm wondering if maybe one of the studs is crooked? Might be worth checking them all for true.
 

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