Removing the rear diff (IRS)

[Martin]

My half shafts won't stay in place. Snap rings look ok, suspicion is that something isn't quite right inside the rear end (Torsen T2).

For the life of me, I cannot get the rear end out. When I put it in, it went in easily (less than 5 minutes). Getting it out however, is proving impossible and after two hours, I still can't get it to fit through the gap. I tried, tilt up, twist slightly, lower down. Now, it is in a position that is jammed and I can't move it in any direction.

Any tips?

Martin

[Bob Cowan]

I just did this same job recently. Turned out to be a lot easier than I thought it would be.

Use a floor jack to get it un-jammed. Point it nose up, and rotate it almost 90*. Should almost fall out, so be careful there. It's pretty heavy.

The alum case is a bit bulkier, so takes a little more wiggeling.

[CHOTIS BILL]

The snap ring not snapping into place is a standard problem and is usually caused by the splines on the half shafts not being cut long enough. If you take a small grinding wheel or thin cutoff wheel and extend the length of the splines about 1/8 inch the snap ring should snap in. A lot written about this on the other forum.

Bill Lomenick

[2bking]

Check out my build thread for some pictures of the process. I only needed to extend the splines about .05.