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Diff Cup Damage

Old 08-30-2007, 02:14 PM
  #1  
souwester
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Default Diff Cup Damage

Hi, after I ran GST into a concrete block, I broke the lower suspension arm and
while I waited for new part to arrive, ran the car with weak suspension arm consequently
I ended up with a cracked differential outdriver ( part DS029 ) coming out of the front gear box.

I took apart the cover from the front gear box and was presented with the front differential.
The outdrivers on either side of this are attached via a plate held on with four little
hex bolts. Problem is as soon as I tried to undo these bolts, I, as we say in Ireland
'wrung' the head of each I tried to undo. Tut tut soft metal[]

Now I cannot disassemble the gear and remove the diff cup.
Has anyone encountered this problem and if so what's the remedy. I'm thinking I'll
have to get a whole new gear box just to replace one diff cup! Thanks.
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Old 08-30-2007, 02:19 PM
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Scott_GTR
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Default RE: Diff Cup Damage

The screws are held in with thread lock and need a little coaxing with heat.

Whack it in the oven @ 200 for ~8 minutes and then give them ago. It does me a treat.

Although if you have rounded off the hex you may have to try something else. []
Old 08-30-2007, 03:00 PM
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souwester
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Default RE: Diff Cup Damage

Yep that's exactly what I've done - rounded off the hex heads. I have to say they
offered little/no resistance then gave out. A bit strange since everything else on the
truck is tough.
Old 08-30-2007, 07:15 PM
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VDub99AML
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Default RE: Diff Cup Damage

get a good quality torx bit and hammer it into the head of the bolt. Do this after you heat the diff. You also can use a little butane torch if you have one handy. Just heat the diff case around where the bolt is which you are trying to remove.
Old 08-31-2007, 07:55 AM
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thurlow
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Default RE: Diff Cup Damage

I ran across this same issue when locking my center diff. My solution worked out just fine. I used a Dremel tool with an emery cut-off wheel, and cut grooves in the heads of the screws, thus making them slotted head screws. Use a good quality screwdriver (prefferably hollow ground), and removing them was a snap.
Old 08-31-2007, 07:56 AM
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mazdab2600
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Default RE: Diff Cup Damage


ORIGINAL: souwester

Hi, after I ran GST into a concrete block, I broke the lower suspension arm and
while I waited for new part to arrive, ran the car with weak suspension arm consequently
I ended up with a cracked differential outdriver ( part DS029 ) coming out of the front gear box.

I took apart the cover from the front gear box and was presented with the front differential.
The outdrivers on either side of this are attached via a plate held on with four little
hex bolts. Problem is as soon as I tried to undo these bolts, I, as we say in Ireland
'wrung' the head of each I tried to undo. Tut tut soft metal[]

Now I cannot disassemble the gear and remove the diff cup.
Has anyone encountered this problem and if so what's the remedy. I'm thinking I'll
have to get a whole new gear box just to replace one diff cup! Thanks.
i was just on sc and reading a mod for these diff's on a savage.
those bolts have loctite on them.
the guys tip for getting them out was to heat the diff in the oven.
it in the general forum so you don't have to join if your not a member.
http://www.savage-central.com/module...wtopic&t=66841

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