I've been reinstalling my diff today, and it simply isn't sliding all the way in. Looked through the Haynes manual and it only seems to imply it's a direct slide in and bolt in job. I'm really confused because when I removed it, I had to hammer at it from the right side of the assembly, essentially just rotating it, because it wouldn't come straight off. I already tried rotating the assembly around when it was in but that didn't help either.
I can get it close, but not all the way flush. When I try to just get the top bolt in it simply doesn't catch. Any help would be appreciated- Really hoping this is a stupid oversight that will get me on the road today.












Thanks!

 

Are your axles removed?

 

Yep, axles are removed, haven't reinstalled anything after I removed the diff.

 

try rotating the driveshaft slightly and keep trying to push it in

 

My driveshaft is disconnected, but I guess I should try rotating the flange, kind of surprised I haven't really tried that yet! If anybody else thinks of something, please fire away!

 

Tried that and it still didn't work. But now that I think about it, if it needed to rotate it to get in, wouldn't that just lock up the gears since they wouldn't be able to get in any other way?

 

It should just go back in.

Maybe make sure nothing fell into the housing that would keep it from going all the way in (I'm sure you've done this already). Also worth looking at the little "dam" on the top of the housing for the vent tube, it's possible that's been bent and is blocking it from going in?

Just stabbing in the dark here, I've never had much trouble getting the diff to go back into the housing... Good luck!

 

Back when these cars were new,i worked as a tech at local Mazda dealer. Replaced lots of axle housings damaged in accidents,curb hits.. sometimes had a hell of a time removing pumpkin from housing on teardown but would slide right into replacement housing. Had it happen other way around too,come out of damaged housing like butter but fight all the way into new one. I found that the tips of the threaded studs in axle housing would catch on sides of mounting holes in pumpkin and hold tight preventing full insertion of pumpkin in housing. What worked for me was using a tapered hand reamer and clean up and ever so slightly enlarge the opening of mounting holes on axle housing side of pumpkin to help threaded studs enter cleanly. Important to insert pumpkin as straight as possible into housing/onto studs and tap on with plastic hammer. Once sure evenly started,use block of wood on pumpkin between stud holes and tap with hammer working back and forth to evenly bring in pumpkin til near flush. Start all mounting hardware then tap home with wood block and snug and torque all retainer hardware. Patience needed,sometimes walking away and coming back in a few minutes to try again makes all the difference. Good luck

 

Kindly disregard this post^^ Just had surgery,on pretty strong meds,was thinking(not too clearly) of a different vehicle. maybe time for a nap...

 

So I got it in- somehow. Just went back to it, stuck it in there, and lo and behold the damn thing just slides in. Whatever, I'll just go with it lol

 

It's an extremely close tolerance fit. If you're not putting it in exactly straight-on then it is going to fight you.

 

haha that's how it is sometimes... just like putting the drum covers back on! pita until you get it