This is a great project - challenging as all get-out, but good, nonetheless.

A few thoughts:

- between Dave Morrison's excellent DIY and tobybul's posts outlining the steps, anyone can do this job...just leave yourself lots of time.

- Dave's write up did not include DIY on replacing the diff seals...mine were shot, so I replaced them. A seal puller is HIGHLY recommended...I struggled with this step for a while, before prying it off and slightly damaging the bearing cover.

- no idea how tobybul was able to reboot two axles in an hour. I had a helper and we worked like MAD to stretch the new Astoria boots over the cone and onto the axle. One is slightly torn at the small end - I am hoping I can still clamp it off and make it hold oil. I could not get one of the four onto the axle...my hands and forearms were so fatigued that I had to wait until tomorrow to finish. Tobybul - you are my hero.

- the pick thingy that is used to pull the c-clips off the ends of the axles inside the diff...get this tool. I ended up forgetting to get it, and using a small hardwood flooring nail, slightly bent at the end, and pulling the threaded nail out (with clip attached) with needle nosed vice grips.

- I couldn't figure out how to get enough space to remove the axle from between the diff and the hub; raising and lowering the diff with a jack is the way to do it. Dave mentions this, but I glossed over it, somehow.

- I covered the open diff with saran wrap. I couldn't get my head around shoving shop rags or paper towel into a bunch of gears. The saran wrap across the open back of the diff works perfectly, especially leaving the diff open overnight.


I hope, for the love of moses, that I can use that boot with the small tear. I don't want to wait for another boot, b/c I have to go back to work on Friday, and I don't know if I can get it in time...and don't want to pay overnight shipping.

That's all for now - I'll update when I finish, or get stuck.

Cheers.

__________________
1984 300D: 275,000 miles (soon to be for sale)

In search of my 1987 300D in anything but white.