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Sierra sapphire cosworth 2wd rear diff partial strip down,how to remove stubs??

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Old Dec 12, 2015 | 09:53 PM
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Default Sierra sapphire cosworth 2wd rear diff partial strip down,how to remove stubs??

Hi,I'm cleaning my rear diff up as it had previously been poorly painted with aerosol paint.
I want to remove the stubs and front input flange so I can have them dipped in paint stripper and zinc plated (bufty)
I have looked at my workshop manual but it doesn't explain how to strip down the rear diff,just the input shaft.
I have the cover off as it had the wrong bolts and the cover is a little damaged and I think I can see a bit of a circlip but it looks tricky to get into.
Can anyone explain how to remove them without specialist equipment or is it a job for a transmission shop to remove them for me?
Thanks in advance,lee
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Old Dec 12, 2015 | 10:30 PM
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There is a C clip on the end of each stub you can tap them off and back on with a flat blade screw driver
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Old Dec 13, 2015 | 05:47 AM
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Dont remove the input shaft nut as that sets the preload on the diff, you would need to get it reset after you refit it


steve
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Old Dec 13, 2015 | 06:28 AM
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Originally Posted by The Youth.
Dont remove the input shaft nut as that sets the preload on the diff, you would need to get it reset after you refit it


steve
There's a second nut under the flange that adjusts the pinion bearings load
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Old Dec 13, 2015 | 11:24 AM
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Originally Posted by The Youth.
Dont remove the input shaft nut as that sets the preload on the diff, you would need to get it reset after you refit it


steve
My manual tells me how to remove that to change the seal but nothing about preload.
It's the genuine Ford cosworth manuals I have but I can't find any info on the diff internals.
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Old Dec 13, 2015 | 11:26 AM
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Originally Posted by 155lee
My manual tells me how to remove that to change the seal but nothing about preload.
It's the genuine Ford cosworth manuals I have but I can't find any info on the diff internals.
Removing the flange doesn't affect the pinion pre load. Under the flange is another nut that adjusts that
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Old Dec 13, 2015 | 11:39 AM
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Great,thanks.
I'll have a go tonight.
Are the stub axles just held in with the circlips you can see,nothing more?
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Old Dec 13, 2015 | 11:41 AM
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Originally Posted by 155lee
Great,thanks.
I'll have a go tonight.
Are the stub axles just held in with the circlips you can see,nothing more?
Yes. If you look at the end of the stub where it go's through its side gear in the diff you will see the C clip. Once the clip is off the stub pulls out
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Old Dec 13, 2015 | 09:01 PM
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Originally Posted by ajamesc
Yes. If you look at the end of the stub where it go's through its side gear in the diff you will see the C clip. Once the clip is off the stub pulls out
You were spot on,pinged the c clips off and out came the stubs,held against the input flange and cracked the nut which came off easily then a tap from behind and the input shaft came off too.
Thanks very much,I can now get the last parts plated.
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Old Jan 26, 2026 | 12:09 PM
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Just about to embark on this very task. Not looking forward to it!
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Old Feb 7, 2026 | 06:07 PM
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Originally Posted by McRod
Just about to embark on this very task. Not looking forward to it!
Good luck
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