Nic Day Posted December 13, 2006 Share Posted December 13, 2006 as you know from all of my diff questions I am about to undertake the biggest spannering job of my life - taking out the diff !!! Now the car is up on stands, I have taken the boot floor out to have a look from the top. All getting a bit nervous now. So I have read everything I can find on here through a big search, also have Myles site printed out for taking out the prop. There seems to be 2 schools of thought. 1 Have to take / move the DD tube and the A frame etc etc 2 it will come out without moving the tube, but a very tight fit etc etc. Now my question is, can I add a 3rd way? After looking at it from the top minus the complete book floor - has anyone taken it out from above?? It looks like it should fit, and it looks easier. Now as my spannering skills are well known to bed complete Sh1t!!! I better ask if this is a silly idea???? cheers Nic Winner of the Largest pair in a non SV 7 (Rumble 2003) here Link to comment Share on other sites More sharing options...
Irrelevant Posted December 13, 2006 Share Posted December 13, 2006 has anyone taken it out from above?? It's my preferred method . . . used successfully, again, just 3 days ago. You'll need the whole floor removed, including the ally section between the front and back floor bits. From this point, basic steps are.......... Undo prop. Take calipers off ears. Undo the DD ears. Undo diff (leave hanging on top bolt). Pop drive shafts out of diff(it'll probably leak just a bit of oil now so be ready). Support diff and take top bolt out. Pull diff out past DD - tis tight but will fit. Job done Edited by - AdamHay on 13 Dec 2006 09:42:30 Link to comment Share on other sites More sharing options...
Nic Day Posted December 13, 2006 Author Share Posted December 13, 2006 YESSSSSSS I have the car up on stands and the complete floor already out!!! - it just looks so much easier to come up from the top and through the boot. So thanks Adam Winner of the Largest pair in a non SV 7 (Rumble 2003) here Link to comment Share on other sites More sharing options...
Jason Plato Posted December 13, 2006 Share Posted December 13, 2006 top tip whilst the diff is out grind off the top corner protrusion @ 45 degrees nearest to the dedion tube . next time the diff will also drop out the bottom past the de dion tube . here is C7 TOP Taffia Area Rep Link to comment Share on other sites More sharing options...
caterhamnut Posted December 13, 2006 Share Posted December 13, 2006 Thats a damn fine idea Dave We have removed a few of these and sometimes it is not practicle to take th eboot floor out - this will make the 'downwards' method much easier! www.mycaterham.com here Videos here 98,000 miles -1st 1.6k Supersport, '95 Motor Show car Link to comment Share on other sites More sharing options...
irrotational Posted December 13, 2006 Share Posted December 13, 2006 Looks like it is all systems go for saturday then --- this is a local sig for local people! Link to comment Share on other sites More sharing options...
Irrelevant Posted December 13, 2006 Share Posted December 13, 2006 Doesn't the build manual say to grind the lump off the back of the diff? All the Caterhams I've worked on have had intact lumps though, so maybe I'm mistaken Link to comment Share on other sites More sharing options...
Nic Day Posted December 13, 2006 Author Share Posted December 13, 2006 Andy - looks like all go for Saturday - hang over or not!!!!! just waiting to hear back from a mate and sort out time. Are you going to pop over aswell??? As for the lump - will have to have a look!!!!!!! Winner of the Largest pair in a non SV 7 (Rumble 2003) here Link to comment Share on other sites More sharing options...
Jason Plato Posted December 13, 2006 Share Posted December 13, 2006 Yes Adam , you need to grind a big lump off the back off the diff so that the diff doesnt hit the de dion tube when in use / suspension compression . but if you then also grind off another section at the top of the diff @ 45 degrees, the diff doesnt foul the dedion in removal here is C7 TOP Taffia Area Rep Link to comment Share on other sites More sharing options...
Nic Day Posted December 13, 2006 Author Share Posted December 13, 2006 new prop bolt - tick printed myles web log - tick sh1tting myself - tick tick car up on stands - tick boot floor out - tick any idea on how to do this - ??? Winner of the Largest pair in a non SV 7 (Rumble 2003) here Link to comment Share on other sites More sharing options...
Englishmaninwales Posted December 13, 2006 Share Posted December 13, 2006 but if you then also grind off another section at the top of the diff @ 45 degrees, the diff doesnt foul the dedion in removal Careful not to take too much off and break through the casting Link to comment Share on other sites More sharing options...
irrotational Posted December 13, 2006 Share Posted December 13, 2006 Nic, if you're doing something in the morning i *may* be able to pop round - but will probably have to help tidy/hoover and all that other nonsense 😳 ☹️ --- this is a local sig for local people! Link to comment Share on other sites More sharing options...
Nic Day Posted December 13, 2006 Author Share Posted December 13, 2006 under the thumb and all those other jokes for you to fill in as you wish!! Winner of the Largest pair in a non SV 7 (Rumble 2003) here Link to comment Share on other sites More sharing options...
caterhamnut Posted December 13, 2006 Share Posted December 13, 2006 Nic - understand your nervousness, but Adam's list above is a pretty good order of events! In the mean time you could give various nuts and bolts (the ones on the car!) a quick squirt of release spray so they soak overnight - just in case! www.mycaterham.com here Videos here 98,000 miles -1st 1.6k Supersport, '95 Motor Show car Link to comment Share on other sites More sharing options...
Nic Day Posted December 13, 2006 Author Share Posted December 13, 2006 Angus - top idea I will do that tonight Also planning on changing rear pads - (need to borrow a wind back tool), scraping and POR15 the underside aswell and greasing my nipples. So I should have a nice clean and re furbed rear end. And a new LSD so donuts coming soon!!! Winner of the Largest pair in a non SV 7 (Rumble 2003) here Link to comment Share on other sites More sharing options...
irrotational Posted December 13, 2006 Share Posted December 13, 2006 nice clean and re furbed rear end --- this is a local sig for local people! Link to comment Share on other sites More sharing options...
dave1968 Posted December 13, 2006 Share Posted December 13, 2006 never mind his re-furbed rear end, unfortunatly I am now picturing Nic with greased nipples 😳 I may need counselling Link to comment Share on other sites More sharing options...
Irrelevant Posted December 13, 2006 Share Posted December 13, 2006 Also planning on changing rear pads - (need to borrow a wind back tool) You don't need a windback tool - a pair of molegrips turning the piston in conjunction with someone pushing the piston down (with a big screwdriver or something) works fine. Just be careful not to damage the piston seals. Link to comment Share on other sites More sharing options...
Nic Day Posted December 16, 2006 Author Share Posted December 16, 2006 Its out!!!!!!!!!!!!!!!! 3 hours myself and my mate martin. In the end took it out from below. No problems at all, just tight to get it past the DD tube. have all the washers saved and know where each of them comes from!!! So not a bad afternoon on a post office xmas party hangover!! So thankyou all for your help and suggestions answering my numpty questions Cheers Nic Winner of the Largest pair in a non SV 7 (Rumble 2003) here Link to comment Share on other sites More sharing options...
caterhamnut Posted December 16, 2006 Share Posted December 16, 2006 Well done mate - once you have done it once it all becomes so clear... Just wait 'til you have to get all thos epesky washers back in, and thread the bolt through 😬 - tip - stick them together with grease, and if there are 2 of you then you might be able to 'hold' them in position with a long screwdriver threaded through from one side while you start the bolt from the other - if that makes sense! www.mycaterham.com here Videos here 98,000 miles -1st 1.6k Supersport, '95 Motor Show car Link to comment Share on other sites More sharing options...
irrotational Posted December 16, 2006 Share Posted December 16, 2006 well done chap - quickly logged in to see if there were any "argh! help!" posts - but looks like its all under control! 😬 Link to comment Share on other sites More sharing options...
Nic Day Posted December 16, 2006 Author Share Posted December 16, 2006 cheers Angus and Andy Good idea about the grease. Just need to book it in with Phil from R&R and then as you say the fun starts putting it all back together. My top tip is to have someone who is good with a spanner alongside you!!!!!! Winner of the Largest pair in a non SV 7 (Rumble 2003) here Link to comment Share on other sites More sharing options...
caterhamnut Posted December 16, 2006 Share Posted December 16, 2006 Say hi to Phil from me! www.mycaterham.com here Videos here 98,000 miles -1st 1.6k Supersport, '95 Motor Show car Link to comment Share on other sites More sharing options...
Nic Day Posted December 17, 2006 Author Share Posted December 17, 2006 Of course I will - I will be watching with interest as he stips and replaces my diff. So what other jobs should I do with the car in bits like this. So far the job lis is Clean, and POR 15 as much as I can Waxoil as much as I can change rear pads grease Prop UJs Anything else??? Winner of the Largest pair in a non SV 7 (Rumble 2003) here Link to comment Share on other sites More sharing options...
Jason Plato Posted December 17, 2006 Share Posted December 17, 2006 call Phill @ R&RT ASAP as he closes for xmas and new year soon - like next Thursday say hello from me too and sorry about the glass outside the workshop 😳 here is C7 TOP Taffia Area Rep Link to comment Share on other sites More sharing options...
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