Okay, I was ABOUT to install a PowerTrax locker. I got the differential cover off and got to the pinion shaft bolt and started going through my wrenches looking for a match. Unfortunately, the closest I came to the right size was a 5/16 and an 8 mm; both of which felt a little loose. The next smaller size wouldn't even come close to fitting over the bolt.

I grunted and I got about 60-70 ft lbs of breaking torque before the bolt rounded off. I was, and still am, very pi$$ed. Is there some weird way to get this bolt out I don't know about? Like is it reverse-threaded or something stupid like that? Also, now that it's rounded off, how do I get it out now?

And, where do I get a replacement bolt if I ever do get it out? Please help me, guys, I'm really stumped!

 

well i know whick bolt you mean, but it isn't a pinion shaft bolt, more like the cross shaft for the spiders. as far as i remember they're 5/16 and usually come right out for me. if it's rounded and you can't get anything on it try welding a larger sized nut on it. or even try a little heat and vice griops before the nut and welding.

 

Sorry, everything from the instructions that came with the Powertrax, to my Haynes and Chiltons manuals called it a pinion shaft retaining bolt.

So it's not reverse threaded, right? I tried vice grips, robogrips, crescent wrenches... you name it. What's this trick about using heat though? Does heating it up help? I want to avoid welding anything, since I've never really welded before, and I don't want to get slag all over the differential and housing.

Any ideas?

 

Have you tried a six point wrench/socket?

 

Okay, I got a six point wrench last night, and a new bolt today. Now all I have to do is get the old one out. I'll try the new wrench tonight, but I'm doubtful since it's already rounded off. I can't believe neither repair manual mentioned the need for a six point wrench...

 

It's not a need, but a 6 point will grip better on any nut/bolt. Smack the head of that bolt with a hammer a few times--it may help it break free.

 

If someone has put thread locker on it. You will need to heat the housing , near where the bolt screws in. The threads aren't very long. If they used red locker on it, it'll take quite a bit of heat to break it loose.