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ZUKIWORLD Discussion Forum => Technical Discussion - Beginner / Repair => Topic started by: Propstothegast on August 22, 2016, 06:23:20 AM

Title: Help! Diff doesnt fit housing and axle doesnt match diff!
Post by: Propstothegast on August 22, 2016, 06:23:20 AM
Hi there,

I havent been active for a while for various reasons, one of which was my suzuki was down with a bad diff and I didnt have the ability to fix it until recently.

My problem is that I ordered parts based on the information I had from the guy I bought it from and none of the parts fit.

I was told I had a tracker 5.12 diff upgrade. But the tracker diff I ordered from a member here (Thanks!) doesnt fit the diff housing in the axle. it hits the back of the housing. Also the axle I ordered is too large to fit the diff.

I think the axle problem is just that I ordered a 26 spline axle and the diff is probably 22 splines.....wish I had known to look for those numbers. But thats not a big deal the axle was cheap.

At this point I am just trying to figure out why the diff doesnt fit and what I can do about it.

Advice would be helpful because the garage that has it doesnt know anything about samurais....They mainly do Jeeps.

1988.5 tintop
I was told 5.12 diffs

It has too many modifications to list but if you need to know specifics to comment please say so and I will get right back to you.

Thanks in advance!
Title: Re: Help! Diff doesnt fit housing and axle doesnt match diff!
Post by: BRD HNTR on August 22, 2016, 04:11:22 PM
Short version of long story.  When I was installing 5.13 gears in a converted Sammy rear differential housing, I had to pound out the step in the back of the housing to get it to fit.
You can see the step in this photo
(http://lh6.ggpht.com/_86HP5-adsWc/SROFfHyeyTI/AAAAAAAACZM/bHCxVsR6iOY/s512/CIMG3116.JPG)

And this is what it looks like after pounding the step out
(http://lh5.ggpht.com/_86HP5-adsWc/SYthGVJo48I/AAAAAAAADBM/V_kNdSVFTu4/s640/CIMG3263.JPG)

If you are installing 5.13/5.12 gears in a Sammy, you will need to get a "Can" to hold the pins in place, or tack them so they can't come out.