I want to know how precisely a replacement differential’s case must match the size of the old case. How tightly must the axle fit into the differential case? Can there be any play at all?
Here’s the situation: I ordered a limited-slip differential for an icy-road upgrade, but when I got the old differential off and tried to press on new bearings, I discovered that the new differential case was slightly larger than the old; the diameter of the sleeve on the outside of the new case (where the bearings must be pressed on) is 1 3/4", whereas the old one was 1 1/2". If I buy new bearings and racers, do you guys think there is any chance the diff case will fit? Also, the inside of the sleeve (where the axle goes in) is 1 1/4" on the new differential, whereas the old one was 1 3/16". That’s an extra 1/16" of play for the axle if I measured right, and of course I’ll need a different set of bearings for the new case. Can this LSD work, or do I need to return it and try again?
Finally, my differential plug appears to have rusted shut. Any advice on getting it open?
Thanks for the expert opinions.