I give up

[philip_g]

I fought this damn diff all day, 4 hours or so to get the carrier out, now I've got not one, but two punches snapped trying to drive the roll pin out and stuck in the hole. I'm putting this damn thing back together.

anyone want a new in box D44 aussie locker? $225.

 

[Frank Z]

Why in world would you pull the carrier to install a lunchbox locker?

 

[philip_g]

Why in world would you pull the carrier to install a lunchbox locker?

something about not enough room to get the pin out inside the housing. Wouldn't have mattered anyway as the nail in the coffin was the roll pin which is now permanently in there.

I swear this worthless thing is cursed.

 

[Frank Z]

Philip,
Simple way to get the cross shaft out is to use aDremet with a small sanding drum (60 or 80 grit) and remove a little material at a time from one toothh of the ring gear until the pin can slide out. A good drift pin punch will drive out even the most stuborn roll pin...provided that you are driving it out from the ring gear side.

 

[philip_g]

Philip,
Simple way to get the cross shaft out is to use aDremet with a small sanding drum (60 or 80 grit) and remove a little material at a time from one toothh of the ring gear until the pin can slide out. A good drift pin punch will drive out even the most stuborn roll pin...provided that you are driving it out from the ring gear side.

banged two of them in there, both broke, the last one I couldn't get out so I ground it off, I have to get to work this week and can't play with it anymore. I couldn't even get the pin to move more than about halfway.
One punch was a sears (made in china) the other a home depot (made in USA) both were pretty weak but they're only like 3/16. The only way I can see now is to put it on a drill press and bore it out for a bigger pin, I haven't got a drill press.

 

[Frank Z]

A drill press won't do you much good at this point. The roll pin goes through the cross shaft...and little fokker is HARD!!

 

[philip_g]

A drill press won't do you much good at this point. The roll pin goes through the cross shaft...and little fokker is HARD!!

but the roll pin shouldn't be, if you can clamp down the carrier I think you can drill a 3/16" hole right down the middle

 

[philip_g]

maybe I'll just take it to a shop, anyone know one they want to get some revenge on? lol.