Removing Front Diff with KDSS

[Jetboy]

So.. I've done one remove/replace cycle in the front with KDSS. The issue is that the KDSS hard lines run inside the cross member where the drive flange needs to fit. For me it was a major PITA to fit through. The only solution I found that sort of worked was to remove the bolts where the lines are attached to the frame on the brackets and try to basically flex the lines a bit. But I get almost no movement even with doing that.

So...

Who's got a better solution? How are you moving those hard lines or otherwise making space to clear the diff drive flange without damaging them? Has anyone used some sort of a shield to make sure they don't get damaged as you have to bend them to slide the flange through?

 

[renau001]

I’m confused, what work are you trying to do?

 

[Jetboy]

I’m confused, what work are you trying to do?

Remove and reinstall the front differential. I regeared. Not happy with the lower gears. So in swapping back. I did this once already. The hard lines on the inside of the cross member make it very hard to maneuver the diff into place. I was hoping there was some easy way to either get them to move a few mm or to work the diff into place I didn't figure out last time.

The pinch point is the drive flange. It doesn't fit between the engine oil pan and the kdss hard lines without moving them a little bit. I could probably do the swap in 2-3 hours but for that issue. I think it took me 30+ minutes to work back in last time. Bench pressing it into place trying to twist it around to find a way to slip it past that point that long killed my arms.

You can't pull the flange or I'd just do that.

 

[atchcraft]

I had a long reply that for some reason didn’t post. To paraphrase; I don’t have KDSS, but having R&R’d my front diff twice, I understand the suck. When I did mine on the ground, I made a cradle for an ATV Jack, and a ratchet strap sling, that saved my arms and gave me more time to finesse it in. I didn’t have KDSS lines to deal with, but I understand bench pressing it and trying to angle it in. I know you’ve probably already thought about this, but I feel your pain.

 

[DigitalVex]

Don't like the lower gears? Might just need to get bigger tires :wink2:

 

[Jetboy]

Don't like the lower gears? Might just need to get bigger tires :wink2:

Yeah. Even with 34s it's just too low for comfortable cruising at highway speeds. If I didn't need to do long stretches of 85mph highway I'd be okay with it. Also 12 mpg...

It's great city and trail. Wish I had a 6th gear in the transmission.