d35 Locker install, I need help

[crawlin91]

another fun filled friday night. Im installing my aussie locker I got the Dana 35 ttb center section out and pulled the e clip and axle. I also removed the bearing cap bolts and bearing caps. at this point it says to carefully remove the carrier but it doesnt seem to budge at all. Ive tried lifting and hitting the housing with a rubber mallet....nothing. Ive also tried slowly rotating the gears back and forth while lightly tugging and nothing.

What am I missing? How do I get the carrier out of the housing?

 

[Hahnsb2]

Sounds like whoever put the gears in use a carrier spreader and it's got excessive carrier bearing preload.A pry bar should pop it out without much trouble.

 

[crawlin91]

ok so say I use a pry bar to pop it out..

1)then when I assemble it am I going to need a carrier spreader to get it all back in?(shims, washers, carrier, etc.) or

2)do I just use less shims?

3)Also how will this effect my carrier bearing preload and will I have to make other adjustments?

Ive never dealt with gears before but according to the instructions if everything gets back in its original position and orientation I shouldnt have to RE-setup the gears.

 

[Hahnsb2]

Without a shim pack and the proper tools to measure them and backlash you shouldn't mess with the shims. Basically you'd line everything up and force it back in or make a carrier spreader. It IS possible to install the locker with the carrier in the housing, it's just a PITA to get the cross pin roll pin out...

 

[Sasquatch_Ryda]

A trick I use at work is to stuff some rags into the ring gear and rotate it around into the pinion. It will force itself out.

 

[Ranger44]

A trick I use at work is to stuff some rags into the ring gear and rotate it around into the pinion. It will force itself out.

Yep, I use the same method.

 

[crawlin91]

dont know exactly what you mean. I tried something similar with a couple shop rags today. I tried rotating it both ways nothing, I also tried pulling again, didnt budge. That bitch is in there. Im contemplating having a shop do it (quoted at $100 full install) as I can see myself tearing some thing to shit prying to get it out and again to force it back in without a spreader.

 

[metalmacguyver]

Just leave the carrier in. The only hard part about that will be removing the roll pin that holds the cross pin in place.