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post #1 of 32 (permalink) Old 02-22-2004, 01:06 PM Thread Starter
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Pumpkin drop/install

Its easy as pie to drop the pumpkin by yourself, but you'll definately need a friend to get it back in...

Following along Dan U's original article, jack up the back end and make sure you've got 8-10 inches between the brakes and the ground once the tires are off.

Start by unbolting and removing the catback exhaust, get it out of your way. Its a 9/16s or a 14-15mm, can't remember off the top of my head.

Then its time for the real work. Put the tranny in neutral and rotate the DS until you can get to 2 of the bolts easily. Put the tranny back in park and yank those two bolts (12mm 12 point bolts). Put it back in neutral and rotate the DS around to repeat the process on the other two bolts.

Now comes the fun. Go to one of the rear knuckles and undo the upper control arm bolt, tie the UCA out of your way and grab the knuckle and pull outward kinda gently. Crawl under the car and use a screwdriver to coax the half shafts out of the pumpkin, I prefer the screwdriver as opposed to just pulling on the half shaft. You'll get it most of the way out, but not all the way unless you're special or something. Repeat process for other half shaft. The knuckle bolts are I believe 21mm and 18mm. An 18mm bolt head with a 21mm nut, but a 13/16s inch wrench will get the 21mm nuts off.

Then undo the two bolts that link the knuckle to the lower control arm in the rear, and grab hold of the knuckle and pull out enough to get the stub shaft completely out of the pumpkin, guide the stub shaft behind the pumpkin (rearward of the pumpkin) and slip the bolts back in to hold the knuckle in its normal spot. Repeat for other side, and tie your half shafts up so they're not sitting on the LCA.

Place a jack under the pumpkin and jack it up to the pumpkin and keep the pumpkin pinned in its area. Unbolt all 4 nuts that hold the pumpkin in (leaving the bracket attached to the rear cover. Then slowely lower the jack and ta da, the pumpkin it out of the car. The 4 lower nuts that hold the pumpkin through the bushings and through the rear bracket at 21mm (13/16s) on bottom and 15mm on top. I unbolted the rear bracket from the frame, or you can just unbolt the pumpkin from the rear bracket using the same 21mm (13/16s).

Installing has a few differences though, and will require a friend for help. Wrestle the pumpkin back up into its mountings and bolt it in its rightful spot, how you achieve this is up to you. Next you'll reverse the process for the DS bolt removal, but you're going to have a challenge of getting the bolts lined up in the flange, but when you do, just get it bolted on. Time for the friend. One of you get under the car where you can reach the half shafts easily. One of you will go to the knuckle, unbolt it completely again and pull it out away from the car, pulling the half shaft with it long enough to have the friend guide it back into the pumpkin. Reinstall the LCA bolts and hinge the knuckle towards the pumpkin while you rotate the half shaft enough to get the splines to engage easy other fully. Then back off the knuckle, reinstall the UCA to the knuckle and count this side as finished (after all bolts are torqued to specs). Repeat for other side.

Make sure that everything is button'd properly and that the differential has the sufficient fluid. Reverse all of the above set of tips.

Changing the speedo gear can be a bit of a vent. Snag a 10mm socket, a 10" extension, and a swivel joint. Just look up at the transmission tailshaft and you'll see the VSS sticking out at a downward angle. Undo the single 10mm bolt holding it in, swing it down and change the speedo gear, and pop that bad boy back in place.

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Last edited by AverageJoe; 02-24-2004 at 10:58 PM.
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post #2 of 32 (permalink) Old 02-12-2005, 09:17 AM
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i know this thread is old but do u happen to have any pics of the removal/installation?

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post #3 of 32 (permalink) Old 02-12-2005, 09:41 AM
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I have had to take my diff out and put it back in by myself many times. I normally put the rear of the car on jack stands and then support the diff with a floor jack. You can lower it with the jack as well as put it back up with the jack. Get a couple nuts started and you're home free.

It is easier with two people though.

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post #4 of 32 (permalink) Old 02-14-2005, 10:31 PM
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ive done it many times myself but im spoiled, i used a lift, and a tranny jack to jack the pumpkin up to the car, i dont even take my catback off anymore to get the pumpkin out, but its smarter to take it off like AJ mentioned

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post #5 of 32 (permalink) Old 02-14-2005, 10:34 PM
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I know, right?! Just pry the cat-back far enough over so the pumpkin clears it and you're good to go!


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post #6 of 32 (permalink) Old 02-14-2005, 11:40 PM
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no need to remove my exhaust...it ends right before the pumpkin

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post #7 of 32 (permalink) Old 02-15-2005, 08:47 AM
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Big-Al if come down to your place and you can help me put mine in. I'll buy pizza and beer and HOOTER wings
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post #8 of 32 (permalink) Old 02-15-2005, 08:57 AM
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Well, the pizza and wings sound good, but I am living at school right now and have no tools, no place to wrork, and no jack/jackstands. Sorry man, there are a few in Charlotte that can hook you up though.

(I'm currently in Greenville, SC)

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post #9 of 32 (permalink) Old 02-15-2005, 10:44 PM
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Quote:
Originally Posted by Big-Al
Get a couple nuts started
Mike and... Joel?

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post #10 of 32 (permalink) Old 02-16-2005, 07:44 AM
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Thats a good one . One UP for (ShadowDragon)
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post #11 of 32 (permalink) Old 02-16-2005, 08:45 AM
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Basicly!

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post #12 of 32 (permalink) Old 04-15-2005, 11:39 AM
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No need to remove both halfshafts either. Just undo one side, and slide it over and off the other side. Nice write up!
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post #13 of 32 (permalink) Old 04-15-2005, 12:24 PM Thread Starter
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Yeah, I know you can just pop one of the halfshafts, but when I tried that method I wasn't comfortable with the bind it wanted to put on the CV joints of the over halfshaft. I also feel it makes the actual lowering/raising of the pumpkin easier when you can take it straight up or down without having to tilt it over and insert a stub shaft then jack it up while sorta rolling it. I seriously doubt either method is faster than the other, but to each their own.

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post #14 of 32 (permalink) Old 04-15-2005, 06:04 PM
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Quote:
Originally Posted by AverageJoe
Yeah, I know you can just pop one of the halfshafts, but when I tried that method I wasn't comfortable with the bind it wanted to put on the CV joints of the over halfshaft. I also feel it makes the actual lowering/raising of the pumpkin easier when you can take it straight up or down without having to tilt it over and insert a stub shaft then jack it up while sorta rolling it. I seriously doubt either method is faster than the other, but to each their own.

ditto i did it with a differential jack at work on a lift and if i did it again id just take off the 36mm nut and remove the half shafts to make it hella easyer, there easy in and easy out, instead of fighting with space

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post #15 of 32 (permalink) Old 04-18-2005, 09:22 AM
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any one have the torque specs for all the nuts?

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post #16 of 32 (permalink) Old 04-18-2005, 10:03 AM
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I like pulling both halfshafts back out of the way. It's really easy to do (3 bolts), and then you can keep the pumpkin level so you don't dump gear lube out of the halfshaft holes in the case. Here's a couple pics I snapped during my install of the 4.10's.





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post #17 of 32 (permalink) Old 04-18-2005, 05:15 PM
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thats really helpfull...never really looked back there to see how things work....should disk brakes be any harder than drums?

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post #18 of 32 (permalink) Old 04-18-2005, 05:51 PM
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easier. move the caliper off and hang it somewhere above -- no worries on bustin your brakeline.

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post #19 of 32 (permalink) Old 04-18-2005, 10:13 PM
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sorry about all the questions...but since i might be down there this weeked...what else is a good idea to look at or change...any bushings or whatever? what do i need to buy so i have everything with me when i start.

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post #20 of 32 (permalink) Old 04-19-2005, 08:30 AM
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One thing I see you're missing in the article. For us ABS guys, there's 1 bolt on each side that needs to come out that's right in front of the halfshafts. Easy to see, they're attached to some long cables...or wires or something of the such.

~Jeff

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post #21 of 32 (permalink) Old 04-19-2005, 11:35 AM
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that wires are for the abs sensor pickup module.

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post #22 of 32 (permalink) Old 04-19-2005, 12:30 PM
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mike whats with the massive spacer???

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post #23 of 32 (permalink) Old 04-19-2005, 09:20 PM Thread Starter
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Quote:
Originally Posted by JeffTBird93
One thing I see you're missing in the article. For us ABS guys, there's 1 bolt on each side that needs to come out that's right in front of the halfshafts. Easy to see, they're attached to some long cables...or wires or something of the such.
Good point. I see how I missed that detail considering my car has no ABS...

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post #24 of 32 (permalink) Old 04-19-2005, 09:26 PM
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Good point. I see how I missed that detail considering my car has no ABS...
I figured that was the reason why. I was just tossing that out there for anyone wondering about them. But don't let it happen again!

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post #25 of 32 (permalink) Old 05-14-2005, 01:12 PM
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i noticed there is a line coming out of the top of the diffy into the frame...

just wondering what it is and how i can remove it



sorry about the quality

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post #26 of 32 (permalink) Old 05-14-2005, 01:16 PM Thread Starter
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Quote:
Originally Posted by smokymance
i noticed there is a line coming out of the top of the diffy into the frame...

just wondering what it is and how i can remove it



sorry about the quality
That line is actually an air vent tube for the differential. Personally, I wouldn't remove it. Besides, its only about 7-8" long, it barely tucks up into the frame at all.

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post #27 of 32 (permalink) Old 05-15-2005, 02:02 AM
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i didnt know what it was...what i meant was that i didnt know how to remove it and replace it on the new pumpkin...so i guess it just pulls out when i drop the old pumpkin and just take it off and place it in the new?

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post #28 of 32 (permalink) Old 05-15-2005, 09:41 AM
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yeah its so the diffy doesnt build up pressure, you can put it anywhere as long as it wont get chewed up by something, if you have a new differential make sure it has a breather on it

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post #29 of 32 (permalink) Old 05-15-2005, 11:57 AM
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yep, the new pumpkin has a hole in it....im just gona use the tube fron the old one

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post #30 of 32 (permalink) Old 05-16-2005, 03:33 PM
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When I changed my diff fuid, I noticed it was weeping fluid from around where the vent tube goes into the diff, so I put a thin coat black RTV around it, then inserted it into the diff when I was done.

Nice and clean now, and it has been four months since I did the work.

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