I have the differential apart now. I took the parts to the machine shop and the plan is to have some round pins made. The pins will be made from 4340 steel and they will be ~ 1/16 of an inch bigger in diameter on the VCU end. This way they'll be press fit into the VCU slots and there will be no slop.
I checked the rest of my assembly for play and there is none. So, if this doesn't fix my clunk, it has to be something else in the tranny itself.
Is there any part in particular you guys want pics of? To get the dif. out, it took me 2 hours (using on hand tools & a slide hammer) and I just followed the instructions here:
Output shaft replacement without tranny pull: EASY
and here:
http://www.3si.org/wiki/index.php/Ch...e_transmission
For the disssembly I didn't even need to remove my downpipe/transfer case. I was able to just pull everything out from the passenger side wheel well. However, I will need to remove my transfer case when reassembling so I can properly lube the end of my 300m shaft (it was a bit rusty).
Quote:
Originally Posted by KORMEX
Welding the coupling is not a good idea at all . when you have yours, off you should consider making sense of my previous post
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If you are referring to the part about punching the pins out and then putting them in backwards it doesn't seem to make a difference. The VCU slots are at least 1/16 of an inch bigger than either end of the pins.