Dana 35 broken lock bolt

[verbdel]

Hello All,

So started the install of my new Lokka Locker today.

Well whoever was inside the rear diff before broke the lock bolt that holds the
pinion shaft in place.

There is only a thread or two left plus the extension that goes through the pinion shaft.
Therfor the pinion shaft cannot be removed. Therfor I can't get to the c-clips, and on and on ...

Any idea's how to get this out ??  4 hours later and I got stopped at Step 1. Not a good start!

Advice please.

[vantagetes]

Place a nut over the broken bolt and tack the inside of the nut to the bolt. Use a wrench on the nut to extract the bolt and replace.

[Bnine]

Reverse drill bit is about your only hope.

Just pray it backs istelf out while you are drilling.

[LLYJ]

Snap on makes a set of titanium bolt extractors that are very short (reverse bit inside the extraction tapered left bolt) - can't say for sure if they will fit but something to consider - mine were about 70 bucks 6-7 years ago - used them a number of times in spots where the other two types (square and spiral) wouldn't fit.

I could loan them but I'm in Lake Louise...


This post requires more cowbell

[verbdel]

Thanks for the advice all.

Anyway I took a large punch and a Big Hammer and smacked the pinion shaft/cross shaft really hard
and broke/sheared off the lock bolt/retainer. 2 hits.

Pinion shaft came right out.

OK on to step 2 !!

[binare]

Hope ya didn't mangle anything else with that solution

[verbdel]

Well it seems the broken lock bolt was the least of my problems.
Got past the lock bolt.
Seems the LS plates on one side had let go.
Not sure why she was still working with no crazy noises and such.

So now I need a new/good used "Open Carrier" for a Dana 35 so I can install the locker I have
already bought.

Any suggestions where to get one ( maybe one of you has one ? ).
Guess I will need the 2 "thrust washers" as well.

Thanks,

[verbdel]

New Carrier and Bearings from Pat's/Gear Centre.
In stock.
$220.oo
Hard to beat I would say.