So I sleeved and trussed my front axle this weekend and pulled all the electrical connections from the casting (per directions) and now I'm fuct...am I really going to have to pull my axles and carrier to get this stupid thing back in and working?

The plunger hooks on the outside of that thin ring correct?

 

Yes, it hooks on the far side of the ring. The carrier will probably have to be removed, but a few people have posted that they got it maneuvered into place without removing the carrier. They never did say if anything was bent or otherwise damaged from their efforts.

 

Yeah I figured :-(

So I just pull out the shafts to clear the carrier - then remove the 4 clamp bolts securing the carrier and roll it out far enough to clear the plunger?

I've never messed with the diff - don't want to mess anything up

 

Carrier bearing caps have to go back in exactly as they came out; left and rights caps in their original places, and top an bottom of each cap as they were. A torque wrench is required.

Pay attention to the shims on each side of the carrier. They must go back in as they came out. Be careful not to damage them. A case spreader will minimize the chances of shim damage. Sometimes a case spreader is not needed, but see if you can source one ahead of time in case you need it.

 

http://youtu.be/3oAFc-_g3ZA

 

Nice dowel pin trick! I wish I could work as fast as that guy in the video.

 

So...can I literally just pry the carrier out about 1/2" to clear the lip of the plunger over the ring?

I'm thinking I won't even have to fully remove the bolts, cap, or shims. Would that work? I know I gotta use something to hold the plunger open before sliding it back into place.

 

Do the minimum to get it done. Pull a little and try; pull a little more, and try.
The only glitch you may run into is not having a case spreader if you need it.

 

Maybe I'll see if I can rent one first. Thanks!!!

 

I shoved a towel in betwen the ring and pinion gears. Used a breaker bar to turn the pinion yoke until it popped out. Reinstall was simple. Mallet and a piece of wood alternating sides.