Stripped some threads in the differential case :(
Thread Starter
Melting Slicks
Joined: Dec 2000
Posts: 3,407
Likes: 2
From: Carmichael CA
Stripped some threads in the differential case :(
It was a beautiful day in Kent. I primed and painted everything...drive shaft, yokes, 1/2 shafts, differential case and cover, etc....metallic black, looks sweeet! Everything was going great, even got the new bearings installed by heating them up and sliding them on (well, they actually were still subborn and I had to use the hammer to snug them in, but they flushed all the way up). Even the carrier assembly wasn't too difficult...the springs were a bitch, but I got some channel locks and compressed them and used a screwdriver and socket extension to pry and tap them in.
Then, it came time to install the pinion, and carrier into the case. First, the outer bearing was falling apart...the basket and bearings would just seperate...I figured no big deal, I could cope with that, and I did. Then when I got the yoke on there is a flat spot hitting the case (I dinged it when taking it off and forgot to fix it). I figured no big deal it will just wear down after awhile. Then I gathered the shims and races to install the carrier into the case. It was a real tight fit...I used a hammer to get it to go (I was desperately running out of time)...and it was almost all the way in, so I installed the bearing caps and bolts. Well, one bearing cap went down smooth, but the other one was stubborn, and the bolts looked like they were going in crooked. I backed them out, and yep...about 3 threads were stripped in the case...not cut out, just reformed. The bolt was in good shape, so I managed to get it to thread through the stripped section and grab some good threads, but the other bolt just stripped about 4 to 5 threads deep, and the bolt tip had about 3 threads gouged and torn.
It was Sunday at 7pm, and nothing was open that had the 7/16 tap. So, I packed it in for the day. Before giving up I discovered that the carrier was too darn tight, so I'll have to pop it out and grind down the spacers to give it some breathing room. I'll get a tap and get some good threads, possibly buy a longer bolt. Actuall, I might be looking at doing a helicoil AND new bolts. Oh well, this is my first differential so I figure it's a learning experience, even if it costs me some time and a tap.
Then, it came time to install the pinion, and carrier into the case. First, the outer bearing was falling apart...the basket and bearings would just seperate...I figured no big deal, I could cope with that, and I did. Then when I got the yoke on there is a flat spot hitting the case (I dinged it when taking it off and forgot to fix it). I figured no big deal it will just wear down after awhile. Then I gathered the shims and races to install the carrier into the case. It was a real tight fit...I used a hammer to get it to go (I was desperately running out of time)...and it was almost all the way in, so I installed the bearing caps and bolts. Well, one bearing cap went down smooth, but the other one was stubborn, and the bolts looked like they were going in crooked. I backed them out, and yep...about 3 threads were stripped in the case...not cut out, just reformed. The bolt was in good shape, so I managed to get it to thread through the stripped section and grab some good threads, but the other bolt just stripped about 4 to 5 threads deep, and the bolt tip had about 3 threads gouged and torn.
It was Sunday at 7pm, and nothing was open that had the 7/16 tap. So, I packed it in for the day. Before giving up I discovered that the carrier was too darn tight, so I'll have to pop it out and grind down the spacers to give it some breathing room. I'll get a tap and get some good threads, possibly buy a longer bolt. Actuall, I might be looking at doing a helicoil AND new bolts. Oh well, this is my first differential so I figure it's a learning experience, even if it costs me some time and a tap.
Le Mans Master
Joined: Apr 1999
Posts: 6,134
Likes: 46
From: Raleigh North Carolina
Re: Stripped some threads in the differential case :( (Rockn-Roll)
There is a special tool called a "case spreader" that is normally required to install the carrier. It spreads the case just about .010 +/- to allow installation of the carrier. Its purpose is to avoid damaging the bolts, threads, and bearings. Check out a factory service manual... the tool description and useage are in there. FYI
Tech Contributor
Joined: Aug 1999
Posts: 15,166
Likes: 3,968
From: Connecticut, USA
Re: Stripped some threads in the differential case :( (Rockn-Roll)
Rock
are you reusing the original spacers? If so be careful they are cast iron and will break if you hammer them. I used a kit from Bair's with the steel spacers to adjust for the preload on the carrier bearings. They should be a tight fit into the housing.
Also the carrier bearing holes can be drilled and tapped for 1/2-13 threads.Tom's does this mod if you call them they can confirm it. Use socket head cap screws if you don't have 6 line bolts.
Gary
[Modified by gtr1999, 10:31 AM 6/10/2002]
are you reusing the original spacers? If so be careful they are cast iron and will break if you hammer them. I used a kit from Bair's with the steel spacers to adjust for the preload on the carrier bearings. They should be a tight fit into the housing.
Also the carrier bearing holes can be drilled and tapped for 1/2-13 threads.Tom's does this mod if you call them they can confirm it. Use socket head cap screws if you don't have 6 line bolts.
Gary
[Modified by gtr1999, 10:31 AM 6/10/2002]
