I'm trying remove the differential from my 2003 G35 Coupe to replace with one containing 3.7 gears. I was able to get all of the bolts off with the exception of one. The bolt/stud that goes from the back of the differential cover into the frame/suspension.

It looked like this bolt was stripped and I tried everything i could think of to get the nut free with no luck. PB Blaster multiple times over a couple days, breaker bars, deep sockets, etc...I couldn't fit the impact wrench in there so finally decided to try to cut/chisel the nut off. I've grinded and chiseled down all the way to the nut/washer but couldnt ever get it to break/crack to allow me to remove the old diff.

Does anyone have any other suggestions? I don't care about salvaging the differential currently on my car, I just want it out so I can put the new one in.

 

Have you looked at these to help you out. Can you possibly drop the rear subframe to have better access to it. Can you take pics of the bolt and how it looks right now. What are your plan to drill it out or tap it.



http://my350z.com/forum/brakes-and-s...-bushings.html

http://my350z.com/forum/engine-drive...tall-pics.html

 

I'll take some pics tonight when i get home and will post them. Well, I was hoping to be able to break the nut by chiseling it in half but that didn't work. At this point i figure either trying to grind down the nut/bolt to where theres almost nothing left so with all the other bolts undone, the weight of the diff might break it loose and let me slide it out. Other option was to try opening the differential up and seeing if there's anyway to remove it from the inside...not so sure either of these options will be successful.

 

Sears sells stripped nut removal sockets. They cut into the bolt and hold it firmly while you break it loose. I used them on my friends lug nuts that were stripped and stuck. http://www.craftsman.com/shc/s/p_101...2_00952166000P Not sure if it would even fit in your cramped space, but you should look into it.

 

I actually bought this set hoping it would help, but no luck. The threading on the bolt was messed up so even had I been able to break the nut free, I wouldn't have been able to get it off the bolt which is why I ended up chiseling and grinding the bolt down. I was hoping I'd be able to break the nut in half and pull the bolt out but that didn't work. I can grind it down even more and hope the weight of the diff and a little force will break whats left of the nut/washer off and let me get the bolt out, but I'm not holding my breath.

I took some pics but left my cord at home so I'll post them up tonight. I'm definitely open to other ideas/suggestions

 

Damn that sucks. Any room for a sawzall or grinder where the bolt is connected to the pumpkin? Sounds like the diff cover is ruined anyways.

 

I'm pretty sure there's not enough room to get a sawzaw in between the diff cover and the subframe. Those two are tight together. If grinding it down even further doesn't work, then looks like I might just have to take it to a shop and have them remove it by taking the bushing and everything out. Not sure what that would cost though.

 

I had my buddy acid jake look at this when he came over last night and he does not understand why the bolt was stripped or got stripped. It should have been a 17mm bolt and come out pretty easily. The bolt threads into the diff cover and goes through the bushing. He said you could try drilling out the screw or just pretty much destroy the bushing and bolt and then just have the weight of the diff snap the bolt. The diff cover is what the bolt threads into and that means diff cover is ruined and bushing will be destroyed. The shop might want to drop the rear subframe to get easy access to it and the bushing. Try traditional ways of tapping it our or drilling it out. you could also try to weld a bolt with nut to the damaged bolt but space it tight now not sure if you can weld or even have welder.



https://g35driver.com/forums/brakes-...-bolt-fml.html