Thanks again for helping keep me on the right track. Fortunately the seal installation tool kit came with that CAD gasket, and the seals as well. Was planning on just installing it with some rtv black to seal it...or would you recommend that special "gear oil" silicone I bought to do the gear housing cover ?

 

Slowly but surely...... Took my time yesterday, didnt have much to work with but got a few things done. First I very carefully installed the passenger side inner axle. I cleaned the splines on both ends first , then put a bit of fresh gear oil on the splines before sliding it into place. I also then installed the driver side axle, I smeared a bit of bearing grease onto the end of the cleaned splines, so that it would pass through the seal smoothly.

Once that was in place I moved back over to the passenger side and installed the new (3rd !) oil seal, I first lightly coated the outside part of the seal and the inside contact area with a tiny bit of gear oil. I pressed it in as deep as seemed I should, the end of the seal is flush with the bevel.

Once the passenger side seal was in I installed the outer axle, which I also had put a smear of grease around the splines that need to go through the seal, just so I wouldnt damage it, I was very careful here. But then realized that I needed to install the shift collar before mating the outer axle to the inner axle. So I slide them apart, put the shift collar on the diff side, and re mated the inner and outer axles.

Didnt get the hubs on yet. I instead moved to the gear housing cover. I used the special gear oil silicone gasket maker and went around all bolt holes and the entire perimeter with a medium to thick sized bead. The directions specify to assemble immediately, BUT only finger tighten all bolts in a criss cross pattern, and wait 24 hours for full cure ..THEN torque to spec (which I havent done yet).

So Next on the list, reinstall both hubs, put the CAD back together, fill the diff, torque the diff cover bolts, and install the new power steering pump. Between today and tomorrow I should be real close.

 

There is a bushing that goes between the axles I do believe... Helps keep them aligned so the collar slides smoothly.

 

I didnt notice one when I disassembled, nor do I see one noted in the service manual.

 

Wonder if they changed the design...... There *should* be a nipple sticking out of one of the axles, that goes into a hole in the other, to keep them aligned. At one point, there was a nylon bushing that went in there, to prevent metal to metal contact..... So long as it fits together snug, and there isn't a bunch of slop, I think that is all that really matters.

 

Yessir ! There is a nipple that mates the 2 axles together. They seemed pretty snug when I put them in, however I will check for slop today. I didnt have any time to put in the last 2 days, so no further progress. Hoping to get it all back together today. Fingers crossed

 

Good Luck.

 

I got a few more things done today, however not rolling yet ! I am struggling with the CAD at the moment.

I installed both hubs today, admittedly I messed up at first, I did not put those metal plates back on before I started in on the hub. I realized this before I torqued down the passenger side. So it was a quick fix. I greased the splines, hub bore and back side of the hub and also coated the bolts in anti seize grease. I got both sides in , torqued down and brakes back on also, after I cleaned the rotors with brake cleen.

The new power steering pump also went in today, But I didnt get any fluid in, nor did I get the new belt on. I tried, but cant remember how I got the old one off... the tensioner bolt is a very weird size lol... Ill get it tomorrow.

I also torqued down the diff cover but have not filled it yet.

The issue at the moment is the CAD. I did re install it today. I did NOT notice any slop or play between the inner and outer axle. I positioned the fork inside the groove in the collar and set it up on the diff side (inner axle). I used the new gasket provided with the seal tool kit, I lightly coated both sides of the gasket with the same gear oil resistant stuff as I used non the diff cover... HOWEVER ***And this is where I could REALLY use help; When I had the CAD off I did NOT remove the vacuum motor from the housing, I did remove the indicator switch. The service manual states to fill the CAD housing with 5OZ of gear oil through the indicator switch hole, BUT..that hole appears blocked by the end the motor shaft ? Do I need to remove the Cad housing again , remove that vac motor and fill the housing before reinstalling ?

 

No. Just fill the diff, and leave it sit for an hour, then, recheck fluid level.

 

Will do !