im dropping the diff out of my05 s2 so i can bring it to the tech thats going to do my 4.77 gear install. everything is unbolted except i can't get the half shafts out of the diff. any help is appreciated

 

Did you have a read here?
https://www.s2ki.com/forums/index.php?showtopic=85687

 

yes i need to pop out the flanges from the diff off

 

If you remove the two bolts on the upper control arm on both sides, you should be able to push the shaft out.

 

Are you trying to:

Remove the alxes from the dif flanges (6 bolts)

Or, remove the flanges from the dif. If you're pulling the dif, remove the 6 bolts on each axle and leave the flanges in place. The rebuilder will deal with them.

 

Best to leave the half shafts in.
No oil leaking out, no dirt getting in.
If you really, really want to.. do it like this:

1 = crow bars (or simular)
2 = half shafts.
They "pop" out, you have to compress the little circlip that holds it in place.
Make sure to mark them left/right so they go back in at the same side.
(but you allready did that when you took the axles out.. didn't you )
Succes

 

#2 is called an output shaft.

 

I just read the Helm manual, and it doesn't mention removing the circlip

 

What he said.

 

RACER Posted on Nov 20 2006, 12:03 PM
True.


RACER Posted on Nov 20 2006, 12:04 PM
Remove it?
You couldn't if you wanted to with the output shaft in the diff.
They hold the output shaft in place, they sit in this little groove in the splined area.
That "splined area" is (one of the) the side gear(s) inside the Torsen diff.

When you push the outputshaft out you compress the circlip

IIRC my service manual recommends replacing the circlips, I bought new ones to be sure, but the "old" ones did not look damaged or anything.
I had to be damn carfull not to mix the old ones with the new ones because you couldn't tell old from new by looking at them.

Tip for the OP:
Replace the output shaft seals too while the diff is open.