Thread: removing rear pinion flange

Originally Posted by Utemad

This is the real deal.

This is how I did it.



The pliers were just to ad depth as the bolt was too long. Not to grip anything.

Looks like I'm in some trouble. The bolt has sheared off insite the pinion flange.

I have no idea how to proceed now, and I am meant to be going on a trip next weekend.

I've tried heating it up with a blowtorch, attack some lockjaws and belting the living daylights out of it, to no effect.

Suggestions needed please.

I didn't need heat. It just pulled out like it is supposed to.

A mate of mine attacked his with a grinder. Cut it into little bits but not sure what his exact procedure was.

Mine had been out 2 or 3 years prior to have a locker fitted along with new bearings. This no doubt made my job easier however ARB didn't need to damage anything to get it out either.

Originally Posted by Wongdai

Looks like I'm in some trouble. The bolt has sheared off insite the pinion flange.

I have no idea how to proceed now, and I am meant to be going on a trip next weekend.

I've tried heating it up with a blowtorch, attack some lockjaws and belting the living daylights out of it, to no effect.

Suggestions needed please.

Looks like you will have to cut it out with a grinder! It's not hard, just awkward. It's a slow careful process. A bolt snapped in mine, that's why I had to cut mine out.

Cheers,
Phil.

Originally Posted by ptaplin

Looks like you will have to cut it out with a grinder! It's not hard, just awkward. It's a slow careful process. A bolt snapped in mine, that's why I had to cut mine out.

Cheers,
Phil.

I'm not really clear how to go about doing that. Did you grind a cut down the centre of the spigot (protrusion thingy)? I'm assuming I would use the smallest grind wheel I can, say 4"?

I think I will refit the rotorflex for my trip next week (even though it makes me nervous to drive with it, but at least I have a spare) and when I get back tackle this grinding job. If I stuff the grinding up the Disco won't be going anywhere, hence the delay.

I don't suppose anyone has any pics of either:
(a) The grinding process in action; or
(b) A complete spigot once it has been removed?

Clark
Try drilling the bolt out with a 6mm drill bit all the way thru then chase the thread with an 8mm tap. This should be enough to clean it all out.
You probably need heat too. Go to Bunnings and get a Bernzomatic yellow MAP gas setup. Well handy and a definite addition to any shed.
Get a cheap slide hammer to. You really need to use at least a grade 8.8 bolt when pulling this or better off, a 10.9

When I get around to finishing mine off, it's going back in with anti seize on it rather than locktite. Stoopid idea the whole thing is anyway....

Using Capitals, the difference between helping your Uncle Jack off a horse or helping your uncle jack off a horse...