I am in the process of tearing out the rear end in my '76. The left output shaft had 3/8" end play hence the task. Once the axle shaft was removed, I pulled on the output shaft to get an idea how much was too much. The output shaft came right out.

I was expecting to find the 'C' clip totally gone. What I did find was a shaft in relatively good condition and no provision for a 'C' clip on the end. The splines were good. There was no groove for the clip. The right side is secure.

Has anyone seen a output shaft with no groove for a retainer clip?


Dano,

yea, yokes that have been worn past the groove.....

You have a lot of metal in the oil. You need to really flush it out. Did the yoke also ware on the outside of the case?

Thanks for the replies. I did notice on the left output shaft did wear on the outside of the case. I will know this weekend the results of the oil and the condition of the other output shaft.

The end of the left shaft looks perfectly machined. There is no mushrooming on the end of the shaft. The splines at the end are at a sharp right angle to the front face of the shaft. There is no chamfered angle. It actually looks like it was lathed that way.

There is some 'blueing' of the area just behind where the splines are located. I think this maybe from heat or maybe the hardening process. I do believe someone had been inside the differential as there is blue gasket maker and regarding the camber cams one is at the back and the other to the front.

How far would the clip be from the end of the output shaft?

Dano,

Here is a pic of one of my old ones that I had to replace because the splines were twisted. You can get an idea of how much material you may have lost.

my original 79 rear end wore past the c-clip in less than 50K miles.

They push against a pin and they ware just like if they are machined.

grinding on the outside of the case is only possible when worn past the clip

You'll find the snap ring stuck in the upper passage for the pinion bearings. If the stub axle wore off more than .050 metal on the outside of the case it will need to be repaired to hold the seal.
Mike

Thank you all for your advice. I got the rear end out and torn down. The output shaft definatly worn down past the clip. It also wore out the side of the case where the seal sits. Good tip Mike.

I have a big problem. There is not enough material to keep the seal in place. Any experience in this type of damage and what did you do for repairs?

Dano,

After a lot of thinking, I am trying to find a way to "build up" this worn down axle seal area on the differential case.

Has anyone had any experience of the case being welded and then machined down to receive the seal? How about it being machined and then a steel insert added? Any advice or comments are greatly appreciated.

Dano,

Talk to your local machine shop about repairing that one, you might be money ahead to buy and good used case. Considering that all that metal went through your bearings, yours will need rebuilt, maybe a goood used diff or a rebuilt one would be an option.

Just find a good used case you will be ahead in the $$$ if you do this., I have 2 used cases just in case I break mine which I did once already. Case was scrap after the rear let go.

Thanks once again for your replies. I have thought maybe it can be machined for a "insert". I will post again under a new heading to see what has been done out there for replace or repair options.

Dano,