Bit of work to do with the newer 3rd member with 4:10 gears before it can be installed.
Here is what it looked like when I got it. Notice it is missing the spider gears and the cross shaft. My guess this was used with a locker at one time, as I never thought to ask why they were missing.
Bit of a mess right? No worries, the aluminum cleans right up easy enough.
When that was done, the axle seals got replaced.
Passenger side
Drivers side
Now for the carrier. Removed the caps after they were marked with a punch top, bottom, left & right. This is very important to do as each diff housing has a matching set of caps just for itself. There is a "V" mark on each cap, but they we're hard to see with all the red goop on them. The corresponding "V" is on the housing next to the caps to match them up. One V points up/down. the other V points to the side.
The caps & thrush washers set aside in a safe place.
Here is all the parts that were missing that have to be installed.
Removed the carrier and placed the ring gear on the bottom so the spider gears can be installed. First are the axle shaft spline gears. These just slide in place on each side along with a thin thrust washer.
To install the other 2 smaller gears and the cup washers, simply slip each on one side thru the opening on the carrier while holding the cup washers onto the gear itself. Now don't let go of them as they will fall out.
Now turn them both at the same time, pinching the centers so they can roll until they are inside the carrier and can hold themselves in.
Now the carrier shaft goes in thru the holes in the carrier. Pushing the shaft in easy until the holes are lined up for the roll pin. the roll pin holds all this together, so get it right the 1st time!
Roll pin installed with a flat end punch pin, tapped ever so gently until it is flush.
Carrier is now ready to go in the housing. Using some red medium synthetic grease, I buttered one side of the thick thrush washers, to help hold them in place on each side. This helps a ton when trying to get the carrier in place.
After placing the bearing races on the both ends of the carrier, the carrier is placed in the housing (with the ring gear to the passenger side). Going straight in as much as humanly possible eases this part. Making sure the pinion & ring gears are meshed, a dead blow hammer was used to tap it in place.
Now for the caps. Going by the markings I made, they got placed back on and torqued to 57 lbs. Specs are 47-67.
Thats it, this 3rd member is ready to be installed.
Getting it back in the TTB Arm.
Since I did the eliminator clip mod, this is installed without the center axle, but if you haven't done that, & your doing this, now is the time to install that axle and the c-clip back in place.
Slipping the pinch bolt back in place, I used it to help place the 3rd member back in the arm. Lifting the housing up at an angle, it was then pushed straight in (still holding it at an angle) until the hooks on the housing were on the pinch bolt. then it was used as a hing, to swing the housing in place, and a tube of Ultra=Black RTV was used on both the TTB Arm, and the housing lip to form a good seal.
Lining up the holes from the front side, the bolts were installed then tightened down in a star pattern.
Letting the RTV dry overnight before adding the synthetic (75-90) fluids. During the drying time, the axles were installed, and the rest of the parts were put back together.
It was finished off with a 4 ft x 5/16" ID rubber fuel line for the breather tube, ran up high into the engine compartment to keep water out.
Sounds like a lot of steps, but in reality, this doesn't take much time at all for this part of this job.
If I can do it, So can you!
