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Old 02-12-2018, 08:28 AM   #6
gaz_moose
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Join Date: Mar 2008
Location: engerland
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its common for the front flange to be 'stuck on' you want to use a puller to pull if off, or smack it with a soft hammer.

I bet who ever swapped the flange over wound the new one on with an impact gun till it went tight (2 ugga dugga's on the gun) which has ruined the crush washer #6 in your picture.

I cant recall the exact terminology but you set the amount of crownwheel and pinion contact/how it contacts by tightening on the crush washer to crush it till its in spec. I cant remember on these diffs if you can resuse the washer (straighten it out in the vice/press) on say an AE86 axle you would set it up with the crush washer then strip it out and machine a solid one then rebuild. if you didn't want it to go noisy again.

be a nice little project for you. im sure it says how to do it in the workshop manual. probably need some engineers blue. try not to ruin the seals as they cost loads.

heating the flange so it expands makes them easier to get on and off.
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