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Old 03-29-2011, 09:56 PM   #1
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Default Getting the diff off the PPF

I've got a 3.9 torsen I'm going to use to replace my 4.3 open. I've got the 4.3 out most of the way, but I can't get it off the PPF. I took the two long bolts out and the short little one holding that weird metal piece to the diff. There's some kind of sleeve in one of the bolt holes, but I can't figure out how to get it out.

Also, how do I get the boots off the axles or get the axles out of the diff?
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Old 03-29-2011, 10:05 PM   #2
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Try hitting sleeve with hammer?

I am interested in how to get the axles out of the diff too. Never done it before.
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Old 03-29-2011, 10:07 PM   #3
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Grab the sleeve and pull it out, it will take some twisting but it should come out. Thats how I did mine. Then the next time I had the diff out it came out much easier. The axles on a 1.6 diff just pop in. There is a spring clip type thingy that you have to push into the splines.
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Old 03-29-2011, 10:07 PM   #4
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Oh yea this happened to me. I thiiiiiink I remember getting a rod and hammering the ring up and out. Or something like that, it was a long time ago.

For reinstall I think I did the same... pushed it in all the way, installed PPF, then hammered it up some.

But can't remember exactly. Just remember it was a bitch.
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Old 03-29-2011, 10:08 PM   #5
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Quote:
Originally Posted by Faeflora View Post
I am interested in how to get the axles out of the diff too. Never done it before.
You pull them out...
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Old 03-29-2011, 10:20 PM   #6
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Having only been able to move the diff around a little while it was attached to the ppf, it seems like the axles extend in and out inside the boot, so I can't figure out how to get them apart. There doesn't appear to be an easy way to get them out of the actual diff housing. I'm sure I'm just missing something.
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Old 03-29-2011, 10:26 PM   #7
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I dont know much about the newer cars whether they are 2 piece like mine, but I just took the four bolts out of the half shafts, pulled those from the hubs, then when I had the diff out I took a pry bar and with a little efforts they popped out. There is that spring retaining thing that keeps them in there pretty snug. Again this was all on my 90. No idea about an 02
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Old 03-29-2011, 10:32 PM   #8
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Sounds like he has the one piece axles like I did.. I removed one of the control arm bolts allowing me to pull the hub away from the differential giving me enough room to remove the axle from the diff. Was a PITA. Get a friend to help. You have to get them to pop out passed the metal ring that holds them (maybe 1/2", use a screw driver or small pry bar) in there, then pull from the actual hard green part of the axle, not the boot or you will ruin them.

Also a note, it may help to unbolt the differential completely, while supporting it with a jack + piece of wood, allowing it to move around more and gain a bit of extra room.
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Old 03-29-2011, 10:40 PM   #9
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Quote:
Originally Posted by FRT_Fun View Post
Sounds like he has the one piece axles like I did.. I removed one of the control arm bolts allowing me to pull the hub away from the differential giving me enough room to remove the axle from the diff. Was a PITA. Get a friend to help. You have to get them to pop out passed the metal ring that holds them (maybe 1/2", use a screw driver or small pry bar) in there, then pull from the actual hard green part of the axle, not the boot or you will ruin them.
Ok, I hear that when I pull the diff downward it gives me enough room to get the axles out. Now I know the chunky green parts come out of the diff, so I should be able to get it tomorrow. It seems like the hard part will be getting that weird sleeve out of the PPF. I tried prying it, but I didn't try grabbing and twisting and pulling. I'll try that next.
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Old 03-29-2011, 10:47 PM   #10
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Yea... it should look like the above when you pull it out. You see at the end of the spline there is a ring, helps secure the axle in the diff. Once you pop it out passed that it should slide freely out assuming there is nothing on the other side pushing it back in. So if you pull from the green part closest to the differential, after the boot, you won't damage the boot. You might want to open the fill port in the differential as well.

At least that is how I've always done it
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Old 03-29-2011, 10:47 PM   #11
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Quote:
Originally Posted by FRT_Fun View Post
Sounds like he has the one piece axles like I did.. I removed one of the control arm bolts allowing me to pull the hub away from the differential giving me enough room to remove the axle from the diff. Was a PITA. Get a friend to help. You have to get them to pop out passed the metal ring that holds them (maybe 1/2", use a screw driver or small pry bar) in there, then pull from the actual hard green part of the axle, not the boot or you will ruin them.
This. To pull them out, you have to push them in a little so the clip is not held up against the housing and then yank it quick and hard. After a few shots it should pop right out. (and yes, I know exactly how wrong that sounded). I couldn't get the sleeve out either, so I just hammered the things you're not supposed to out of the PPF. I wasn't keeping the PPF anyway. It's an option, but Mazda says if you do, you need a whole new PPF. I'm not really sure why. If you wanted to be extra sure it was solid, you could always weld them after popping them back in.
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Old 03-30-2011, 01:11 AM   #12
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unbolt PPF from transmission.

Remove differential and PPF as a single piece

Remove differential from PPF outside of car.

The first car I took the PPF sleeve out of, I had to remove it from the car, it still took half an hour to get the sleeve out with some crazy *** techniques.

The second car I did this too, the sleeve simply levered out of the hole with just a little bit of effort.
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Old 03-30-2011, 01:15 AM   #13
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two words: pry bar
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Old 03-30-2011, 01:17 AM   #14
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Quote:
Originally Posted by fooger03 View Post
The second car I did this too, the sleeve simply levered out of the hole with just a little bit of effort.
This. Now, just saying, but the factory basically said that anytime the PPF is pried off of the diff a new one should be installed.

Really, it does.
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Old 03-30-2011, 01:44 AM   #15
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A quality pry bar, BFH, and air hammer. My removal and install for MMR mounts was epic lol.

Best way we found. Removal: unbolt transmission side first. Install: bolt up differential side first.
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Old 03-30-2011, 05:01 PM   #16
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Axles comes out with a prybar, just use caution not to damage the area around where the seals go. Aluminum can be quite soft.
I thought that lowering the diff would give me the room i needed to get the shafts out, but i had to jack it up on its mounts again and remove the control arm bolt as well as loosening the hub to a-arm bolt to get the axles out and clear of the diff.

Getting it loose from the PPF had me stumped because I did not want to follow the directions in the service manual and remove whole PPF as a unit.
I, as others have mentioned already, removed those collar nuts from the PPF by threading the long bolts back in and tapping them out. I do not understand why I now have wrecked my PPF and expect to install it again with no ill effects...

Heres a picture of my diff removed. The infamous metal sleeve in the picture seems to be glued with metal resin glue or something and I could not find a tool that would reach in there to try to wriggle it out or something...

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Old 03-30-2011, 09:47 PM   #17
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I got my diff replaced today. It took me a while to get it out because I didn't disconnect any suspension bolts and I was working by myself. I eventually got it out and while I was waiting for the parts place to show up with my axle seals I decided it was a good idea to undo one of the bolts that holds the top a-arm to the hub, and that gave me enough room to get the diff back in. I had trouble getting the left axle back into the diff, but I got it eventually. I almost left the garage this afternoon without putting oil in the diff, but then I remembered and filled it. A dry differential would not have been a good plan.

Getting the two sleeves out of the diff was an adventure. The longer one came right out while I was trying to get the short one out. I ended up getting the short one out by pounding it with a socket on an extension. The new diff came with a long one, but I had to use a bearing press to get the short one in. It really didn't want to go and I feel bad for whoever has to get it out someday.
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Old 03-30-2011, 10:26 PM   #18
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Winning!
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