Hello again.

Iím not thinking at this stage of the process that the inner locating tube will be terribly corroded. The truck lived most of its life in a semi-arid environment in western NSW.

What I am finding as I poke away at the gap is a loamy mix of dirt and oil. It would likely have had enough moisture ingress in there over the years to form a bonding paste with the help of some surface rust from the tube and housing. The lake of atf/distillate that I irrigated it with for several weeks probably added to the mix as would the penetrating fluid that I have been firing up into the working face over the last couple of days.

It is a laborious process picking away at it chip by chip - needless to say - but Iím getting there. As noted, Iím about halfway around the bottom profile getting in to a depth of about 25mm. It would be nice if it could be cut away using a hacksawing motion, but thatís not the drill. Rather, it is a case of picking away at the face of the cut and occasionally cutting through at the point where the housing diameter reduces a fraction.

The next half is probably going to be a bit tougher because the housing base isnít perfectly centred to the tube - or vice versa given the way these things were built. The next half is almost touching the welds around the tube base. So, getting the blade in will get progressively harder - plus the front diff housing is progressively sited below the handle of the keyhole saw reducing the potential length of stroke.

Iím actually hoping that once Iíve cleared, say, about three quarters of the way it may respond more positively to some sideways pressure from the drift and sledge - sufficient to release or failing that be more responsive to another round of jacking.

Anyway, the earlier question remains alive - can you reassemble a relay from the top? Or must it be effected from the bottom of the housing?