rear diff problems

bovay173 · August 26, 2004

hello everyone, i have a little problem on my hands with my 1992 k1500 silverado 4x4 reg cab. I was doing simple rear brake job and noticed that the wheel seals were leaking so i went to change out the wheel seals. When i took the diff cover off and examined the the diff. it had teeth marks in it like the pinion gear was eating at it somehow, and the retaining bolt for bar inside the diff was broken, maybe on of the teeth grabbed the bolt and twisted it ( just a guess) anyway i cant get the axle shafts out because the rest of the retaining bolt is stuck and the diff bar between the axle shafts won't come out. I need to know what to do, if i replace the diff with a limited slip will it get the same marks as the one i have in there now. And if i should replace the diff, how do i get it out if i cant get that bar out or the axleshafts? I think that the marks in the diff also are the cause to a vibration at 60mph and above. any help anyone could offer me would be great.

citydriver · August 27, 2004

Welcome to the Forum

Wish it was under better circumstances though

I used to use different methods to get a broken pin outa a diff.....used to be common, especially when the last person in there over-torqued it....

If the head broke off flush with the carrier, I would use a Dremel tool and grind a slot in the bolt so that I could get a regular screw driver on it..or use a small chisel and try to work it out.

If the pin broke deeper inside, I would try a left handed drill bit, sometimes the drill would catch and back the rest of the pin out, or a set of bolt extractors would sometimes work also.

In the worst cases that the pin would not budge, I would burn the end of the pinion shaft with a torch...This method really sucks cause you need to make sure the gear lube is all washed out so it doesnt catch fire...GOOD LUCK