Diff rebuild or Second Handy

[JoergM]

Ok, tonight is the night.

My slide hammer arrived and I am going to remove the carrier from the case.

I understood that the holding brackets of the carrier as well as the driveshaft have to be back in the same position as I would have taken them off.

What about the carrier itself? Does it matter that I have the pinion in the back and the carrier back together in exact same position or is this secondary?
Not really sure, gut feeling would say it is irrelevant but due to sensitivity of the other parts I just don't want to make things worse.

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[Grippy]

It depends on how far your pulling everything apart, if your just pulling carrier out and changing bearings then your good, just slap it all back in, just keep an eye on where and which side the shims go etc. You won't need a slide hammer to get it out, a.gentle pry and she should fall out.
How are you getting the bearings off? I cut mine, split the race with a chisel, then put the whole show in my Engel on freeze and heated the bearings, they then slipped on, no press needed.

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[JoergM]

Originally Posted by Grippy

It depends on how far your pulling everything apart, if your just pulling carrier out and changing bearings then your good, just slap it all back in, just keep an eye on where and which side the shims go etc. You won't need a slide hammer to get it out, a.gentle pry and she should fall out.
How are you getting the bearings off? I cut mine, split the race with a chisel, then put the whole show in my Engel on freeze and heated the bearings, they then slipped on, no press needed.

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Thanks Grippy. Don't want to change the bearings (at least not planned). Just want to clean it up and treat rust spots.
Once done I will slide it back in.

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[JeanLuke]

Keep us posted please.

I think I will be replacing my rear pinion bearings soon.

[JoergM]

Ok, the carrier is out. As you said Grippy, the slide hammer was not necessary once I took off the drive shaft.

It even worse than I thought and the air locker is already quite rusty. Lucky me only the outside frame but not the area where the rubber ring actually lock the differential.

I can remove the rust, that's not the problem.
However, the surface is already affected and not really Smooth anymore but reminds me of my face when I was in puberty.

I just wonder how I can smoothen it again without simply scratching it off which would leave scratch marks.

As you can see the seals are also affected so I will need to get new seals as well.

And finally some of the paint inside of the case is scratched off and I want to patch it up. Which type of paint would be best for this or should I simply leave it and just remove the rust?

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[JeanLuke]

I would not try to paint it. The oil, if you keep water out, should prevent rust.

[Straubz]

since you have it all apart you could look at installing some outer seals like these http://www.jeepkonection.com.au/JK-D...y-USA-ALY11102, no idea how well they work or if they work with the wj.