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Old 14-04-2011
lastplace lastplace is offline
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Join Date: May 2009
Location: Nottingham
Posts: 93
Default Diff gear pinion

I had the same problem it's the norm .
only way is as already said . I used a 4mm pin punch this is the right size to pass through the Gear, it will bend the E clip and deform the shim, you will have to ballance the Diff case on a Vice, but one good sharp tap and the out drive comes out, its just a bit doggy on the plastic diff case, i have had to do the twice and the diff case's are still fine.

Durango have updated the thickness of the shim that sites behind the gear from 0.5mm to 0.8mm to take some of the slop out of the outdrives so while your working on the diff you may as well get the new ones . I think they have used the same part number.

when rebuilding i used a swiss file to ease the gear slighly you will find it goes onto the outdirve the wrong way very easily then at the last bit it gets tight so when fitting the correct way round its tight all the way down making it very hard to get off again. I think the hex bore in the gear might be slighly tapered making it a tight fit, don't file too much or the pinon will be too loose and could cause more problems.
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