Models: all, Years: all

The differentials of the Pinzgauer were originally build with gears which run steel on steel (Exec I). This design showed some lubrication problems over time and an improved version with a sintered bushing was designed to replace it (Exec II). Exec II was installed as standard and you can verify this by a look see through the drain plug hole.

If the truck didn’t get the upgrade (which makes the differential stronger too) this is the procedure to do the upgrade:
Sit the axle assy on the floor or on a bench , then support the lower case with wood blocks so that the axles assume a straight line out of the axle assy. Remove the axle boots & seals by removing the screws and sliding them out onto the axle beams.

Next remove the rear locker & front cover arrangement. Mark this cover for "top". Observe the two screws on the end covers, (countersunk allens). Remove the top ones ONLY. Now remove the snap ring from the front of the input shaft. Before you go any further grasp the pegged socket area of the input bearing and try to lift it. If there's lift you will need input shaft support bearings (expensive so beware) Now remove the 8 off allen cap screws holding the top cover in place. Give it a sharp tap in various areas, once loose lift it off. Now make notes. Like--- Identify front of lower case, identify front of upper case, mark them if unclear. Also note the snap ring grooved end of the input shaft is the front. OK - Now. Remove the lower c/s allen screws and tap out the end plates. Identify the front plate from the rear. Lay it face down on the bench. The input shaft will now flop down into the case. With an assistant, hold the shaft amidships so to speak, then lift out one complete axle half. You can now lift out the input shaft and drop each input slip pinion and their adjustment shims into their respective end cap plates.

To remove the old differential pinion arrangement, put the shaft in some soft jaws/vice and back out the allen bolt to the last thread. Now with a decent size hammer "give the thing the shaft" with a good blow to the allen head. This will dislodge the holding trunnion and you can then knock the rest of it apart with a brass drift & hammer. To reassemble use a press, (nice). Just go careful not to trap the bronze bushes.
Tighten to 60lbft (80Nm). Reassemble the whole thing as in reverse order. Check shaft end float before mounting the cover, it should be almost zero to .004" (0.1mm) end float.

For the step-by-step photo instructions by Jim LaGuardia please click this line! Caution, long load times

Contributed by Dennis Williams (text) and Jim LaGuardia (photos)