advice wanted on diff

[AndyC]

Output shaft comes out quite easily with a generic slide hammer bearing puller, although it would be unusual for most home mechanics to have one.
Seals cab be driven in using generic seal/bearing drifts but if you have the Lotus specific one it's nicer.

[bash]

In the 18 years Ive had and serviced my car I've never used a 'special tool'. From memory, I didn't use one when I fitted my diff, so Alan?Andy are right. My advice is find another garage.
But, my wife sometimes thinks Im 'special', Im not sure if thats good or bad, and sometimes says Im a 'tool', Im pretty sure thats not good.
Hi ho.

Bash

[alanbell]

marky,
I have gone to the trouble of finding another diff, 3.9 off a 90/91 excel that was written off about 7 years ago and was working before the accident which would not have been severe enough to damage the transmission. call me on 01592742967 and I will give you the details and how to contact the vendor. if I do not hear from you I will assume that you are no longer interested. I did send you a private message about this but I cannot find it amongst the correspondence between us.
alan

[marky]

Thanks Alan - I have now purchased the diff that you found along with a gearbox which I also need ( noisey gearbox! ).

A big thank you to the two other members who offered help, advice and diffs. The matter is now fully resolved and I am happy with the outcome.

Mark.

[AndyC]

Obviously it's good to talk, and even if things don't go smoothly all the time it's possible to rescue the situation.

[marky]

On my 87 car there is a chassis bar running right under the diff front to back - looks like a bolt on after-thought to add strength.

Is it possible to manoevre the diff out of the car around this part or do I have to remove it??

Can I get away with just removing one exhaust link pipe or do I need to remove both?

Thanks - Mark.

[Pete Boole]

You do have to remove the link, and I'm pretty sure you need to remove the exhaust as well - it certainly makes everything easier!

Pete

[marky]

Thanks for that - I had a feeling that would be the case.

Replacement diff has arrived and has a new nut on the nose so I am hoping the nose seal has been done.

Cant get the fill plug to move at the moment - lots of WD 40 - try again tomorrow.

The whole thing is a lot bigger and heavier than I expected ( must be about 30kgs ) think I may enlist the help of my mechanic to get them changed over once I have the replacement ready to go.

Marky.

Just realised that the nut on the nose would look new because its completely enclosed and protected by the propshaft - never mind it was a nice idea!!

[AndyC]

Keep in mind the weight and imagine the situation.
You're under the car which is on carstages so wheels approx 50cm off the floor and you've removed most bolts but put a rope in for safety. The rope goes round the diff and will not come off and you have it above the subframe and have hold of it the other end. You remove the last bolts thinking you can lift it, your back goes into spasm and the diff slips, you move well lout of the way. the diff swings on the rope like a pendulum and swings directly at your face but stops a couple of inches short of hitting you.

The above is one way to realise you really want two people if you're removing it without the aid of a transmission jack.

[marky]

Sounds like the voice of experience - think I will lean from yours - rather than trying it myself.

Have decided to enlist the help of my mechanic with full garage facilities.

Will prep new diff as best I can. have removed the two shafts from the diff with two crow bars - dead easy - no damage and no special tools. Oil seals look quite worn but still holding - will replace them. Rather concerned that the fill plug may have been over-tightened and may not budge!

Mark.

[robertverhey]

the output drive shaft can be replaced without removing the diff, three special tools and plastic hammer are needed as is a dial gauge to measure radial and axial run out on the output shaft flange. as I have not had to do the job myself I do not know if these items can be bypassed. in fact as I do not have a ramp the question of bypassing special tools is, for me, academic.

Is it really this complex? If re-using the same shaft I would think it's just a matter of knocking out the axle with a suitably positioned drift, prising out the seal from the diff housing and then replacing seal and axle......or is the seal integral with the bearing? It's been a while......

[marky]

No - it is that simple! - shaft levers out very easily - so long as you are careful - two levers one either side - the only thing to watch out for is the thin metal dirt shield as it comes out.

Seal is immidiately accessible and can be pulled out easily with a standard seal remover or just levered out with a large screwdriver - again comes out quite easily.

Not going to attempt the input seal though!!

Mark.

[AndyC]

If the fill bung is a pain then just remove the cover when the diff is out, you can then be sure of getting it out.

[marky]

Thanks Andy - I have the shafts and old seals out but I am not buying any new parts until I get the bungs out.

I noticed on the parts List there is a spacer between the bearing and the seal but these are absent from my diff! - not sure whether to buy them and put them in or just re-assemble it as it was with new seals?

Cant move either the level plug or the drain plug and rather than risk damaging them too much I am going to enlist the aid of my friendly mechanic. If he cant move them with his array or tools then I will take the cover off - I presume the gaskets are no longer available so I would need gasket sealant.

Mark.

[AndyC]

I think SJ do the gaskets, so would a Toyota dealer. The same would be true of the air vent or bung if you need them.