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240: Dana Differential Swap?

Hello, all. I have an '82 240 sedan with a bad limited slip differential (LSD), the result of the previous owner running different sized tires on the rear for who knows how many thousands of miles. The differential is completely shot as a result and the car can barely make it around corners, let alone be considered safe to drive.

I want to replace the bad LSD with a conventional differential. Sourcing a replacement is not a problem for me, but I'm not sure what would be the best way to proceed from there. It seems I have but two options:

1) Replace the _entire_ rear end with an intact unit from another car.

2) Attempt to replace just the differential, keeping the existing rear end intact.

Option 1 would not be easy. It means removing coil springs, disassembling the multi-link rear suspension, dealing with old bushings and bolt removal, supporting the vehicle's weight, etc. A nightmare job given that I don't have a lift in my garage!

Option 2 sounds like a lot less work, but I have no experience dealing with installing a differential. What does it take? I know that bearing pre-load, gear alignment and such is critical... is this something that I can do with hand tools with the carrier (rear end) still in the car, or would I be opening up a can of worms?

Any advice appreciated.

tx

StV
Portland, OR






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New 240: Dana Differential Swap?
posted by  St Vincent  on Sun Mar 25 04:15 CST 2007 >


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