Front differential
 

Need to do a front differential rebuild on my 2001 3500 4x4. The factory service manual says I need a case spreader to remove the differential housing. Is this true or can it be pulled/pryed out, carefully? That's an expensive tool and the only one that would prevent me from doing the pinion shaft and side gear replacement. And pinion gear bearings and spacer(s)? since that is just jiggling up and down and whatever I else I find that needs replacing.

Thanks in advance. You guys know your stuff.

Its gonna depend on how worn your bearings are when taking them out. I haven't done a D60 in these trucks, but when I did the d44 in my Ford, I had to fab up a spreader to remove and install the carrier. I can't remember off hand, but I think the preload was around .015", and I was dealing with an ARB, so I didn't want to be hammering on it. I also had a D61 from an old Ford Van, I didn't need to spread the case to remove the carrier on it.

I uploaded a pic of the spreader I made. 1-1/2" square tubing, 3/4" all thread, and we used 1/4" bolts for the pins. Cut the head off the shouldered bolt, and used to nuts to lock it to the closest side of the tubing. Needed the clamps to keep it from flying apart. I'm sure if I had made it out of plate instead, and had the allthread on the diffside of the spreader, I could've gotten away without the clamps, but the tubing was free. Not sure on the D60, but you're not supposed to spread more than .020" on the D44, I'd imagine its similar.

This shouldn't cost more than $15. I was lucky enough to have scavenged this stuff from work a couple months earlier. Couldn't find any place in town to rent one. I did see one on E-bay a while ago going for $230!

I pry all mine out and use a 2x4 and hammer to set it back in. Take your time and get it square and it will come out and go back in fairly easy.

I love it. As technologically advanced as these trucks are a 2x4 and a hammer are still some of the best tools to work on them. Gotta love the irony of that one. [laugh]

Thanks for the info. Didn't want to start getting into it, then run into a problem. Need to start pulling it apart this weekend and start ordering parts. Thanks again.