Front Differential seal

coolasice

Well-Known Member
#1
Ok Guys, i have a bit of a dilema... replaced my pinion seal a few years ago and it never fixed the leak on the front differential. I now believe it is a bad case sealant in the 2 diff halves. Has anyone had to reseal their cases? Wondering how much trouble it will be to do. Anyone believe it would be possible to do without removing the differential entirely from the truck? What kind of time am I looking at in regards to this?
 
#2
It's gonna have to come out. Those that have done the diff swap can say that it can be a b!itch of a job. I have found (and added to FAQ) this write-up:
How to remove front differential
 
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coolasice

Well-Known Member
#3
It's gonna have to come out. Those that have done the diff swap can say that it can be a b!itch of a job. I have found (and added to FAQ) this write-up:
How to remove front differential
I've seen a few videos online about how to remove it some say you can take it out by just moving the engine over a few inches other say you have to pull it out the top. I know the first thing I got to do is get that darn disconnect off the passenger side. I don't think it's ever been removed.

How much does the differential weigh?
 
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coolasice

Well-Known Member
#5
About what my ex-wife now weighs, better bring a hoist or a crane :crackup:
funny guy :blinkhuh: gonna be tackling this next month most likely... just need a few days off to get er done.... might have to register my motorcycle just to be sure i have some kind of transportation....
 
#7
Front diff is not heavy at all. Its under 40. Only thing I could find was all the pieces...

Front Differential, bearing support and shaft: 50lbs 11.5oz
 
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coolasice

Well-Known Member
#8
Front diff is not heavy at all. Its under 40. Only thing I could find was all the pieces...

Front Differential, bearing support and shaft: 50lbs 11.5oz
Sweet,. I know it was aluminum so couldn't be too bad. I almost ran it dry this year, so Def need to fix it.
 
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coolasice

Well-Known Member
#10
Ok,. New dilemma... Busted the disconnect removing it, got all the pieces out and got the shaft out of the pan... Now I can't get the damned diff to separate from the pan... All 4 bolts are out, axle is out,. But the damn thing is seized to the pan... Any tips and pointer for how to proceed from here?
 
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coolasice

Well-Known Member
#11
EUREKA! IT FINALLY CAME OUT! what a mess.... could only find a very trace amount of original sealant on the case halves. Right now it's setting with the rtv seal, going to be torquing in 20 mins... then tomorrow it'll be new seals in the dif and a new yoke. supposed to rain so not very good weather to reinstall....
 
#12
Sucks about the broken disconnect. Been there done that. Glad you got the diff out though, that would have been an even bigger and more expensive pain to deal with if something there broke.
 
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coolasice

Well-Known Member
#13
Sucks about the broken disconnect. Been there done that. Glad you got the diff out though, that would have been an even bigger and more expensive pain to deal with if something there broke.
Oh yeah,. I was pretty annoyed at how hard it was to get out... What helped the most... A hatchet... I couldn't get my chisels to wedge in between the bolt holes because it was so stuck,. Used my hatchet and a sledge an it worked like a champ.
 
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coolasice

Well-Known Member
#16
Making progress... Diff is back in with all new seals and yoke.... Just have the rad and fan assembly to put back in to the engine bay and that end is done. Suspension still needs to be reassembled but the stupid company I ordered my disconnect from said they would ship it USPS didn't... It went ups ground instead.... So I'll get it 3 days later (Monday instead of Friday) then I should.

On a side note.... I haven't been able to locate the damned coolant sensor near the firewall... Any clues as to where I should be looking from?
 

mntegra01

Well-Known Member
#17
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coolasice

Well-Known Member
#19
finally got the ECT sensor swapped... what a bitch that was. If the secondary air tubes weren't there it would have been much easier. Most of the truck is back together. Just waiting on the disconnect to arrive and i'll be all finished... quite a pain in the ass.
 

mntegra01

Well-Known Member
#23
Only place I recall seeing something like that is around the battery hold down on a GM, not necessarily a Trailblazer, Envoy, Rainier
 

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