TR4/4A Differential clatter-solid axle

[Telly]

When I let off the throttle on my TR4 solid axle I get this loud clatter which goes away immediately by giving the car a little throttle. I pulled the diff cover plate and confirmed the pinion gear is hitting the carrier.

While I did replace the pinion seal, I rechecked the castle nut torque and it's 100 lbs.

Is it possible to pull the pinion gear away from the carrier without completely disassembling the diff?

Thanks!

 

[bobhustead]

This system needs to be completely pulled apart and rebuilt. The upper pinion bearing has failed and the lower has also or is about there.
Bob

 

[titanic]

I had the same thing happen on my TR6. I replaced the pinion seal and after driving maybe 30 miles, a loud clunking sound happened on deceleration. An autopsy revealed that the end of the pinion was moving to the rear and contacting the carrier. There was no damage to the bearings, but a lot of metal particles were produced . I am still scratching my head about the cause of the incident as the nut was torqued to spec and the locking wire fitted.
Berry

 

[TomMull]

While I did replace the pinion seal, I rechecked the castle nut torque and it's 100 lbs.

Is it possible to pull the pinion gear away from the carrier without completely disassembling the diff?

Thanks!

That's what torquing the nut is supposed to do. I suppose you could try removing the flange, checking the splines and then re-torquing that nut. There should be no end float. It should also spin freely. If it moves or binds, damage to a bearing caused the issue, which will require a tear-down.
Tom

 

[TR3driver]

The good news is that you don't really have to have that special case spreader tool. The carrier can be removed with some big pry bars. (This is an IRS diff, but the same process works on solid axle. I just forgot to take photos when I did the TR3.)

To reassemble, tap it into place with a brass hammer working from side to side.

The bearing separator for the head bearing isn't too expensive

https://www.harborfreight.com/14-piece-gear-puller-set-30305.html