Anyway to do this cheaper?

[alwaysFlOoReD]

It's been a real long time since I had a rear apart. I think if you can get the axles out you should be able to get the ring gear and carrier out. Then you may be able to use a magnet, tap with a hammer or figure out some other way to get the broken bolt out.

 

[shortzt]

What we've used in college some is a really long drill bit, like 2 foot long, long enough to be able to flex some so you can drill out the pin, granted it ruins the cross shaft but usually not the carrier, I don't think you can get the clips out with the shaft in, because of the angle they go in on, as to avoid hitting the spider gears, easiest thing would be to get a new rear end, another way I've seen work is actually drill out the cross shaft so you can see the end of the retaining pin and tap it out with a chisel, good luck on what ever choice you make

 

[Snoranger]

After looking it over some more...

The shaft is probably toast since it looks like it has been beat on with a hammer 10,000 times.

I wonder if I get a good, and I mean good drill bit..

If I could drill the shaft out to where the bolt is?

As you can see from this photo, the hole is not that deep on the shaft.

The hole goes all the way through.

Your best bet is to grind the end of the shaft until it clears what's left of the bolt. It's a hardened shaft, so most drill bits are useless.

 

[black_demon69]

After looking it over some more...

The shaft is probably toast since it looks like it has been beat on with a hammer 10,000 times.

I wonder if I get a good, and I mean good drill bit..

If I could drill the shaft out to where the bolt is?

As you can see from this photo, the hole is not that deep on the shaft.

read thishttp://therangerstation.com/tech_library/cross_pin_retaining_bolt.shtml

 

[Mark_88]

read thishttp://therangerstation.com/tech_library/cross_pin_retaining_bolt.shtml

Wow...nice find! I've seen some really useful documents in the Tech Articles that I didn't know existed...

I had to rep you for that !

 

[black_demon69]

Wow...nice find! I've seen some really useful documents in the Tech Articles that I didn't know existed...

I had to rep you for that !

thanx back at you

read all tech articles awhile ago and somewhat remembered that

 

[don4331]

Purple:

I don't know how far you have progressed but I used to see this failure regularly.

One wheel would be spinning like crazy (ice/mud); then hit traction (pavement); the spider gears would spin the cross bolt and shear the bolt.

My solution was to undo the caps, allowing the differential to slip out enough for access.

Then using a mirror/flashlight, check to confirm the cross shaft was straight (insert appropriate adjectives when it wasn't). Then drill bolt out; I used a bit really close to the same size as the cross pin bolt shaft to ensure it centered (didn't have the fancy kit on the tech page). Remove repeatedly to clear chips...

When gods were shining on me; after drilling just a pilot hole; I would push grease through that hole and the broken piece would "float" out... (Alternate was dental pick through the hole).