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 with Bill Johnston Changing Stock Sidegears
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 When
upgrading to a beefier set of front axle shafts, it isn't just a quick swap
of the shafts. The kits that are out there require a gear change inside the
carrier. The stock inner axle shafts in the front of the Samurai are 22
spline. The upgraded axle shafts out there are 26 spline. No big problem if
you can source some sidegears from a stock rear differential. One word of
warning - to get this right you will need to know how to set the gears up
right after you are done. Here is how you get to the sidegears. |
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  The
side bearing cap bolts and the keeper is removed next. |
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  Next
comes the side bearing cap and retaining ring. This is done for both sides. |
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  Pull
out the carrier and remove the ring bolts. |
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  Flip
the carrier over and remove the ring gear. This has to be done to allow the
differential pins to slide out. |
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  Open
the case by removing the retaining bolts. Pull off the top half and you will
see the first of two sidegears. |
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  When
swapping out the gear, make sure you use the shim from the gear that comes
out. Transfer it to the new gear. |
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 Here
is another view of the size difference. Except for the opening, the gears
are identical. |
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  Here
you can see how the 26 spline axle shaft fits the new gear.But now we have to go deeper to find the second gear. |
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  Slide
the pins out and remove the center block. |
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  Remove
the spider gears, but be careful not to lose the thrust washers.The other sidegear is down at the bottom. Remove it and swap out the shim just like the other sidegear. |
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  It
all goes back together the same way it came apart. The trick to getting the
spider gears lined up on the pins is to insert the pins enough to hang the
gears on them. Don't forget the thrust washers... |
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  The
long pin will only hold one of the gears. You can use a little bearing
grease to 'stick' the thrust washer to the gear. This will give you a little
more control as you finish the install. |
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  Drop
in the center block and slide the pins all the way through. |
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  Once
everything is seated, the top ( with the new gear) is dropped back into
place.Replace the case bolts and then the ring gear. |
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  Once
the ring gear bolts are torqued to factory specs, reassemble the side
bearing caps and make sure you don't cross thread the bearing adjuster
(ring). |
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  After
you set the backlash, lock the ring in place and torque down the bearing cap
bolts. |
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  Just
to make sure you didn't get anything mixed up, check the size of the
sidegears with an axle shaft before putting the differential back into the
axle housing. You don't want to find a mistake hen you have it all back
together... |
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03/08/08 10:05:52
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