Electra V8-350 5.7L DSL (1983)
As the lock screw hole in the pinion cross shaft is within .150" from the end of the shaft, a die grinder with a 1/4" carbide bit can be used to grind a
groove through the end of the pinion cross shaft exposing the lock screw. A 1/4" die grinder is a commonly available 28,000 to 30,000 RPM tool similar
to a router. Both electric and air powered die grinders are available from power tool sources. This tool and bit is also useful for elongating holes in steel.
etc.
FIGURE 2
1.
Wrap the ring gear in a shop towel and place towels around case assembly exposing only the end of pinion cross shaft. This will protect the
differential internal parts from exposure to metal grindings. Refer to Figure #2.
2.
Inspect and correct any fuel leaks in area of tank and fuel lines, as grinder will cause sparks.
3.
Grind a groove through the end of the pinion cross shaft exposing the lock screw. When lock screw is exposed use a punch and hammer to drive
out pinion cross shaft past the lock screw with the case on an angle so shaft will clear pinion gear head.
4.
In most instances, the broken piece of lock screw can be removed with the case still in the housing.
5.
Clean all traces of grindings from housing.
6.
Install new parts as required and reassemble differential.
The suggested labor to remove a broken pinion shaft lock screw from either a standard or limited slip differential is .4 hr.
