78 series cruiser. Unable to get rear axle back in.
Submitted: Saturday, May 10, 2025 at 16:04
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Member - lyndon NT
Hi All
I have a 78 series Troopy. I have just replaced the rear bearings, hence have had both axles out. On the drivers side I am unable to slide axle back in due to a shim that has fallen down blocking about a 1/4 of the axle housing. I had this happen many years ago and phoned a guy I knew, ex mechanic. He's no longer with us. Anyway, my memory was that I just had to slide something in (broom or similar) and push the shim/washer up and back in position, I then slide the axle in. Not moving this time though.
I have had the axles out a couple of times since then without any problem. Unsure if I've had both axles out at the same time as I have now though.
I initially thought it didn't want to budge due to the twisting of the car due to being jacked up. Since then I have tried a variety of different
wheels jacked up, on the ground etc. No luck.
Vehicle has factory lockers and the locker is on the side of the diff in question.
Thanks for your help.
Sorry, no picture, haven't been able to get a clear image down the axle tube. Shim is just before the diff spline.
Reply By: Member - Duncan2H - Saturday, May 10, 2025 at 16:12
Saturday, May 10, 2025 at 16:12
Is this the same problem?
https://
forum.ih8mud.com/threads/rear-axle-gear-help.1360932/
AnswerID:
647892
Follow Up By: Member - lyndon NT - Saturday, May 10, 2025 at 16:18
Saturday, May 10, 2025 at 16:18
Hi
No, I don't believe so. There are other threads on that site that talk about a similar issue, but then go round in circles. Last time I'm sure I just pushed it up with a broom or similar. Folks talk about pulling out the diff lock etc etc. I never had to do any or that....
FollowupID:
928974
Reply By: Allan B (Sunshine Coast) - Saturday, May 10, 2025 at 16:31
Saturday, May 10, 2025 at 16:31
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Lyndon, try lifting the shim with a broom handle while someone belts the diff housing with a big hunk of timber.
However, do not be tempted to strike the diff with a hammer etc..
AnswerID:
647893
Follow Up By: Member - lyndon NT - Saturday, May 10, 2025 at 16:37
Saturday, May 10, 2025 at 16:37
Excellent idea Allan. Might just work. When can you pop over and lend a hand?
Just uploaded photo.
Cheers
Lyndon
FollowupID:
928975
Follow Up By: Allan B (Sunshine Coast) - Saturday, May 10, 2025 at 16:43
Saturday, May 10, 2025 at 16:43
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Starting to rain here Lyndon…… maybe tomorrow or later?
Doesn't look too bad in your photo. Have you tried rotating the axle whilst gently pushing it in?
FollowupID:
928976
Follow Up By: Member - lyndon NT - Saturday, May 10, 2025 at 16:49
Saturday, May 10, 2025 at 16:49
Weather is beautiful ATM, if you hit the road early tomorrow you should be here by next Saturday :-)
Yes, tried rotating, but shim needs to be lifted. I like the timber idea, will have to wait for a second pair of hands. Fairer half on the turps at the neighbours.
FollowupID:
928977
Follow Up By: Allan B (Sunshine Coast) - Saturday, May 10, 2025 at 16:54
Saturday, May 10, 2025 at 16:54
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…."Fairer half on the turps at the neighbours."
At least someone has the right idea.
FollowupID:
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Reply By: Member - lyndon NT - Saturday, May 10, 2025 at 16:36
Saturday, May 10, 2025 at 16:36
shim
AnswerID:
647894
Reply By: RMD - Saturday, May 10, 2025 at 17:22
Saturday, May 10, 2025 at 17:22
Lyndon
Not sure what you have rotated, But with the other wheel off the deck have you turned the tailshaft to make the crown wheel carrier rotate and therefore placing the side gear shim, which is off centre by an amount at the top and it most likely will then creep down on it's oil film drag. I wouldn't be hammering or bashing anything there.
It will be a cupped/dished washer and you are seeing the convex side. Maybe a steel rod or aluminium tube smaller than the offest can administer a corrective movement to the washer/shim/ Place some grease on the end so it adheres to the internals and will tend to keep the washer there in place, once corrected, and allow the axle to be inserted.
AnswerID:
647895
Follow Up By: Member - lyndon NT - Saturday, May 10, 2025 at 19:45
Saturday, May 10, 2025 at 19:45
thanks, i'll look at again tomorrow. A bit rooted now.
FollowupID:
928979
Follow Up By: Member - lyndon NT - Sunday, May 25, 2025 at 16:32
Sunday, May 25, 2025 at 16:32
You were on the money. Problem solved. Really not sure what I was doing on the day. But was certain that both
wheels were up, HB off, out of gear, but TS wouldn't rotate? Maybe stuck? Maybe I was just stuffed and doing something wrong.
Anyway, cheers. Axle back in.
FollowupID:
929162
Reply By: Max E - Saturday, May 10, 2025 at 20:39
Saturday, May 10, 2025 at 20:39
It is a part of the diff lock. Best practice is to lock the diff before removing the axle to prevent the problem.
What I have read is to taper a broom handle to get is back in position. Make sure the diff is not locked.
AnswerID:
647896
Reply By: Andrew L - Thursday, May 22, 2025 at 11:07
Thursday, May 22, 2025 at 11:07
Try the broom handle with end ground to a point, with it inserted, get the locking collar that’s moved back to being centred, then lock the rear diff. This will hold the collar central long enough to get the axle started in the collar, unlock the diff again allowing the collar to spin and axle to engage diff Centre spline.
If you pull the axle with diff unlocked, this can happen, and with it unlocked, you can’t get the centre out of the housing either. Best wishes.
AnswerID:
647968
Follow Up By: Member - lyndon NT - Sunday, May 25, 2025 at 16:29
Sunday, May 25, 2025 at 16:29
Hi Andrew
Can you just clarify what you are saying for the next time I'm doing this. Not trying to be a smart arse, but just to be certain. I think you may have made a typo.
Are you saying I'm kind of stuffed either way?
Thanks
Lyndon
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