I have just spent 2 very frustrating hours attempting to rebuild my rear differential after replacing the main gear.
The issue I am having is that the new gear appears to have a slightly smaller inner diameter than the old one where the planetary gear case fits into it.
The old one is very easy to fit and take apart whereas the new one is very, very tight.
So tight in fact that the only real way I found of screwing the case on is to kind of sit it resting gently on top and then go around each screw giving each half a turn until they pull the case into the slot on the gear.
This has the drawback of the gear getting pulled on at an angle that does eventually straighten up once all 4 screws are tight but something in this process is causing the planetary gears not to mesh correctly and I either end up with the gears slipping (too loose), locking up completely or locking one way.
I have eventually given up and had to resort to leaving an oily mess all over my kitchen table which I suspect is not going to go down too well in the morning.
Has this happened to anyone else? I feel like my only option is to take my rotary tool to the inside of gear to try and widen the diameter a little. My only worry there is that I have no metal working experience and possibly don't even have the right tools for the job (I have no clue what all the tips for my tool are supposed to be used for ). I'd also be worried that I'd make it even or something and end up with a leaking diff.
The issue I am having is that the new gear appears to have a slightly smaller inner diameter than the old one where the planetary gear case fits into it.
The old one is very easy to fit and take apart whereas the new one is very, very tight.
So tight in fact that the only real way I found of screwing the case on is to kind of sit it resting gently on top and then go around each screw giving each half a turn until they pull the case into the slot on the gear.
This has the drawback of the gear getting pulled on at an angle that does eventually straighten up once all 4 screws are tight but something in this process is causing the planetary gears not to mesh correctly and I either end up with the gears slipping (too loose), locking up completely or locking one way.
I have eventually given up and had to resort to leaving an oily mess all over my kitchen table which I suspect is not going to go down too well in the morning.
Has this happened to anyone else? I feel like my only option is to take my rotary tool to the inside of gear to try and widen the diameter a little. My only worry there is that I have no metal working experience and possibly don't even have the right tools for the job (I have no clue what all the tips for my tool are supposed to be used for ). I'd also be worried that I'd make it even or something and end up with a leaking diff.