Use a screwdriver to pull...
Use a screwdriver to pull the axles toward the center. This will allowthe C-clips to drop out so the axles can be removed.
Trying to upgrade our operation, we obtained a mini-spool kit from National Drivetrain. This kit contains four pieces. National Drivetrain also has a nice package containing bearings, spacers, and gaskets. We were lucky--our bearings were in good shape. This rearend must have been used only during the week and never on Saturday night.
Inspecting the National Drivetrain parts showed them to fit each other properly. The square blocks having the cross pinholes are slightly harder steel than the splined parts. This should give us good wear.
The axles only need to be...
The axles only need to be pulled out this far. Good practice, however,would be to remove them and replace the old oil seals.
One problem we encountered was the lack of a chamfer in the square blocks. The cupped spacers that originally rode behind the spider gears have an internal lip. The spider gears have a chamfer, or notch, for this internal lip. This greatly aids assembly because the spacer is captured by this chamfer when it is slid in place in the carrier.
Grinding a chamfer in the area where the pin fits allows reassembly much like the original. I have heard of racers leaving out these cupped shims or driving the parts in with a hammer and punch. Neither of these options is correct. Leaving out the spacers can create slack and thus wear. Forcing the parts together can cause damage.
Grind a chamfer in the rounded...
Grind a chamfer in the rounded end of the square block. This isnecessary to make the lip of the cupped shim fit and stay in placeduring installation. Leaving this shim out will result in prematurewear.
Grind the chamfer in the square block until the spacer fits on the curved surface as it did on the spider gear.
Clean the outside of the rearend housing. It is much easier to keep the inside clean if the outside is clean. With the cover off, rotate the gear carrier so that a small (5/16-inch head) bolt in the carrier is visible. This bolt holds the cross pin, which goes through the spider gears. This pin locates the axles and keeps the C-clips in place.
Removing this bolt turned out to be a chore for us. Even the properly fitted wrench rounded off the head before the bolt turned loose. The solution turned out to be the use of a hammer and chisel. The chisel is angled so the hammer blow turned the bolt the right direction to loosen. Once loosened, locking pliers finished the job. By the way, this bolt was replaced the same way it was removed.