Front diff removal ,How?

jason thompson · **Posted:** Sat Apr 26, 2008 10:33 pm

OK here is the deal the wife will be out of town for a week this is going to be my chance to get some "work done" on the KJ
I am thinking about going in for front and rear True Tracks
while this is not my top choice for the rear she will not know it is there

Now back on topic
My gear guy said that he would prefer that I pull the front diff and bring it to him
well he said it would probably save me several hundred dollars if I did it so how hard is it?
what comes out?
can I do it but keep the 1/2 shafts in and pull them when it is out of the Jeep or will there be no need to pull them
I can not see why I would not need to pull them but I only know how to pull apart a TJ dana 30 is it the same just IFS?
he said that if I do it this way it may be $150-$200 per axle because he can do it on a bench and not looking up saving his neck and me $50-$100 per axle

The rear is simple

tommudd · **Posted:** Sat Apr 26, 2008 10:41 pm

Front is pretty simple really, pull off everything like you are doing a lift, I didn't pull the struts just loosened them and pulled over some. of course removed the tie rods, sway bar ends, clevis brakes spindle
Once you get under there you can see
but short run down
remove half shaft hub nuts
you can keep the lower control arms on ( manual says to remove) but you have to take the front bolts out, have to do that to get the bracket bolts out, loosen the rear ones and you can pry it over enough when the time comes to remove the diff. bolts.
remove the half shafts,
skid plates,
vent hose from front diff,
unbolt the front driveshaft,
then the bolts holding the front diff in, 4 if my memory is correct, of course there are brackets holding the front diff to the chassis, but remove those bolts , the bracket will need to come off after you have taken it out from under the KJ then to get into the cover.

I know very short description but thats about it, I know you have been under enough vehicles to do it
PM me with any other questions

I need to do a complete write up some day on this. Spray everything good now and let it soak the rust off that is if you have any rust we broke one of the lower control arm bolts ( very expensive) trying to get it off
I keep thinking of little things but thats about it!
Tom

snowsport · **Joined:** Tue Oct 18, 2005 11:52 pm **Posts:** 1211

If you do this jason, could you take some pics?

tommudd · **Posted:** Sun Apr 27, 2008 2:33 pm

[quote="snowsport"]If you do this jason, could you take some pics?[/quot

pretty straight forward, what you see when you lay under the front of the KJ is what you get, nothing really hidden

KJ04 · **Posted:** Sun Apr 27, 2008 7:46 pm

Just start removing bolts until there are no more and it falls on you, then it's out. :lol:

tommudd · **Posted:** Sun Apr 27, 2008 8:11 pm

KJ04 wrote:

Just start removing bolts until there are no more and it falls on you, then it's out. :lol:

Pretty much it isn't it !!!!!! I tried to have Jon lay in the right spot so it would drop on him, :oops:

I mean so he could hold it from falling, but he kept moving......dang youngster!!

If you can do a lift you can do a front diff R&R I think. Common sense of course comes into play which ...some have :roll:

Jeepjeepster · **Posted:** Sun Apr 27, 2008 10:23 pm

tommudd wrote:

KJ04 wrote:

Just start removing bolts until there are no more and it falls on you, then it's out. :lol:

Pretty much it isn't it !!!!!! I tried to have Jon lay in the right spot so it would drop on him, :oops:

I mean so he could hold it from falling, but he kept moving......dang youngster!!

Thats great.

Rush345 · **Posted:** Mon Apr 28, 2008 3:18 am

tommudd wrote:

KJ04 wrote:

Just start removing bolts until there are no more and it falls on you, then it's out. :lol:

Pretty much it isn't it !!!!!! I tried to have Jon lay in the right spot so it would drop on him, :oops:

I mean so he could hold it from falling, but he kept moving......dang youngster!!

If you can do a lift you can do a front diff R&R I think. Common sense of course comes into play which ...some have :roll:

Not meaning to contradict you my friend but I'm afraid your over simplifying this operation. As in the description of SEX IN and OUT repeat if needed. :-)r

Front diff removal ,How?

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