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Front differential drivers side output shaft

Tiny
CARL DUNKIN
  • MEMBER
  • 1992 CHEVROLET SILVERADO
  • 4.3L
  • V6
  • 4WD
  • MANUAL
  • 265,000 MILES
I have replaced the seal, but the output shaft does not want to go back in, it contacts the clip and I am afraid to hit it too hard. I was checking it again. I believe I need to bevel the edge that goes through the c clip.
Friday, June 3rd, 2022 AT 1:04 PM

14 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,254 POSTS
Hi,

You should be able to tap it into place without doing anything to the clip. If you look below, I provided the directions for the removal and replacement of the output shaft.

Take a look through the directions and see if they help. Also, if you are using a rubber mallet, you won't damage it.

Let me know.

Take care,

Joe

See pics below.
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Friday, June 3rd, 2022 AT 10:37 PM
Tiny
CARL DUNKIN
  • MEMBER
  • 18 POSTS
It came right out with a screwdriver gently prying behind it and cleared the frame without lowering the case, but it will not go back. There is a square lip where the gear teeth start and I think it is hanging on them.
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Saturday, June 4th, 2022 AT 6:40 AM
Tiny
CARL DUNKIN
  • MEMBER
  • 18 POSTS
I have torn down ball joints, tie rods, pitman arm idler arm etc. This has me stuck it has been twenty years since I did one of these. I'm 66 and should be fishing but could not afford to pay to have this fixed.
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Saturday, June 4th, 2022 AT 6:44 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,254 POSTS
Hi,

The square lip you mentioned, is it right at the end of the axle? If that is the case, I'm not sure how that would prevent it from going in. Does it go in at all? Are the splines aligning?

If you could upload a few pics of the parts you have, it may help me.

Let me know.

Joe
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Saturday, June 4th, 2022 AT 9:32 PM
Tiny
CARL DUNKIN
  • MEMBER
  • 18 POSTS
The splines are aligning it goes in all but a half to threequarters of an inch. The very end of the shaft is round but the edge is not beveled like the splines are to allow the c clip to slide over I have dressed the end, but it was raining Saturday, so I did not get to try it I have a nice asphalt drive going around my house but no garage or shade tree. I will let you know if it works.
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Sunday, June 5th, 2022 AT 3:09 AM
Tiny
CARL DUNKIN
  • MEMBER
  • 18 POSTS
I will send a picture later today.
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Sunday, June 5th, 2022 AT 3:11 AM
Tiny
CARL DUNKIN
  • MEMBER
  • 18 POSTS
I finally got one of my endoscopes to work and what looked like the clip sticking up a little was a broken part hanging over the splines. I got the big piece out, have to check on the little piece. One last question, if I remove the seal, should I be able to slide a new one in? From the looks of the clip, it has been broken for a while, probably what caused the seal to fail.
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Sunday, June 5th, 2022 AT 1:20 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Hi,

To install the seal, I would recommend using a seal install tool. Some use a block of wood to keep it even. However, it won't simply push in. It will require being tapped in with a light hammer.

Let me know if that helps and how things turn out for you.

Take care,

Joe
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Sunday, June 5th, 2022 AT 10:45 PM
Tiny
CARL DUNKIN
  • MEMBER
  • 18 POSTS
I was referring to the new clip I will have to remove the new seal I had put in using a large socket.
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Monday, June 6th, 2022 AT 5:21 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,254 POSTS
Hi,

Sorry about that. If you replace the clip, it should go in easily. It still may require a few taps with a rubber mallet or similar.

Let me know how things turn out for you or if I can help in any way.

Take care,

Joe
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Monday, June 6th, 2022 AT 8:01 PM
Tiny
CARL DUNKIN
  • MEMBER
  • 18 POSTS
I used a Dremel tool and ground of approximately one quarter of the width of the clip on the outside edge beveled the square edge of the shaft to match the end of the splines the placed a folded paper towel into the gear to stop the clip from going into the diff. Used a pair of hemostats to slide the clip into the inner shaft pushed it in place with a screwdriver removed the paper towel the shaft slid in all but the last half inch a tap with a hammer and it clicked in! I'm making notes in my motors man. For next time. The clips they are giving out at the dealers are too big and have to be altered and still will not go in installed on the output shaft.
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Thursday, June 23rd, 2022 AT 6:36 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Carl,

First, thank you for the update. It never should have been that difficult to do, but I'm glad you got it taken care of. I wish there were more people like you that when confronted with a problem are able to find a solution. It does sound like they sold you a clip that was too big.

Regardless, please feel free to come back anytime in the future. You are always welcome here.

Take care,

Joe
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Thursday, June 23rd, 2022 AT 8:12 PM
Tiny
CARL DUNKIN
  • MEMBER
  • 18 POSTS
The clip for this differential has been discontinued no dealer or parts store have them. I tried them all even online.
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Friday, June 24th, 2022 AT 4:16 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,254 POSTS
Wow, I would think that would be a common part considering how many of these vehicles are on the road. I wonder if an aftermarket company will pick it up someone needs to.

Regardless, take care of yourself, and please feel free to come back anytime in the future. You're always welcome here.

Joe
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Friday, June 24th, 2022 AT 7:47 PM

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