Changing Jimny Rear Diff

hey guys
i've purchased a complete rear diff fitted with an auto locker as below;



unfortunately i have little idea of how to fit it.

i've read the how-to on replacing rear wheel bearings as to how to tackle a big part of it ( www.bigjimny.com/images/documents/changi...ar-wheel-bearing.pdf ), but have a few questions if i may.

- will i need to remove the back brake lines/components/hand brake cable, or should i be able to pull the axle out far enough with them still connected ?

- does diff 'lash' need to be inspected ? the diff was removed working from the car, but not sure if this is a setting that changes with wear or from vehicle to vehicle.

any tips you guys can share for the swap would be greatly appreciated, i have literally never undertaken anything on a diff before & would like to be able to complete it myself if possible.

GraphicX wrote: hey guys
i've purchased a complete rear diff fitted with an auto locker as below...

unfortunately i have little idea of how to fit it.

i've read the how-to on replacing rear wheel bearings as to how to tackle a big part of it ( www.bigjimny.com/images/documents/changi...ar-wheel-bearing.pdf ), but have a few questions if i may.

- will i need to remove the back brake lines/components/hand brake cable, or should i be able to pull the axle out far enough with them still connected ?

- does diff 'lash' need to be inspected ? the diff was removed working from the car, but not sure if this is a setting that changes with wear or from vehicle to vehicle.

any tips you guys can share for the swap would be greatly appreciated, i have literally never undertaken anything on a diff before & would like to be able to complete it myself if possible.

I managed to do mine (fitting an ARB air locker) without removing the brakes / handbrakes -





I found that a couple of battens of wood held the shafts out far enough for me to ease the diff out... and back in again...

A willing helper is also useful -



Youngest daughter Bethan wielding a crowbar

Regarding the 'lash' / setting off the diff...

It's not vehicle specific, as it's all contained in the diff you're swapping out*, did the seller tell you who had fitted the auto locker? Did they do it themselves or use a garage / specialist...?

* You have checked the ratio is the same as yours? Jimny diffs do differ slightly across models I believe -

www.bigjimny.com/images/documents/transferboxratios.pdf

That would suggest just the automatics / 2005+ electric transfer box models though, so you should be ok?...

thanks for that, i actually recall seeing those images in your build thread now.

& yep have checked the ratio, it's 4.09, apparently that's the norm G series manuals.

don't know if he had a shop do it or did it himself, will message him to find out. is the best bet with the lash to remove my diff, take both diffs to a diff mechanic & have him check they're the same & correct if necessary ? or would it be highly likely all G series manuals would have the same lash ? sorry but i'm fairly clueless on the lash, i think i have a slight idea on what it is (the amount of play in the gears ??), but no idea how it's adjusted etc.

It should be ok if he's been driving it and offroading it, but I'd just double check with the seller for your own piece of mind...?

I've done a few myself and as long as the diff is stripped and rebuilt carefully the lash / settings shouldn't be affected...

Rockwatt's (07921 222635) your man if you do want it checked...

Dave