Rebuilding A Differential

[TomR]

I plan to change the ring and pinion on my S4SE. Have successfully rebuilt other diffs before but I get the impression that extra care is required for the Elan. Is the factory manual the best source for info? Can someone point to links describing the operation and possible pitfalls? Thanks.

[types26/36]

Tom,
The w/shop manual is the best source that I am aware of but it refers to special tools which I doubt you have (or can get)
I have worked on a couple of diffs mainly replacing seals and carrier bearings but have not replaced the crown wheel & pinion or pinion bearings as its these that require the Ford special tools.
To replace the pinion seal you will still need a rotary torque gauge to set the pinion bearing pre-load and a D.T.I. (dial test indicator) to set the backlash when replacing the carrier bearings.
The manual goes on to tell how to check the tooth contact with engineers blue if the crown wheel & pinion/pinion bearings have been changed.
You can take a chance and just refit the original shims if you do replace the crown wheel & pinion but MARK everything as you disassembly and hope for the best.
Brian.
64Elan/72Sprint/J.P.S.Europa

[steveww]

You will need special tools and and big press. Getting the crown wheel and pinion lined up properly is a bit difficult

I would just take it to a specialist. I think it would save you money in the long run.