HELP! First off, i blew my spider gears up...opening up the case to check them out, i find the screw that holds the pinion mate shaft in is broken inside!! only about a half inch of threaded bolt came out. So now the shaft is stuck in there!!! what do i do? cut the bottom of the pinion shaft and try to expose the nut? is there another way to get the carrier out with out removing the pinion shaft?
are you sure it was suposed to be a bolt I have seen both bolts and roll pins holding in the cross shaft.
sorry I just re-read you post and you said only part of the bolt came Out. about the only thing you can do is pull the carrier drill a small hole in the broken bolt using a drill press and then use an easy out.
350 Chevy engine vortec heads Holley Pro-Jection
Ford T-18 Tranny
Dana 44s Detroits w/ 5.89s
38" Swamper SX
Lots of other random things and dents
Actually they make a little convenient kit to take care of that pesky bolt.I had that happen to me on a dana 60 with c clip axles.so there was no way to pull the carrier to drill it.But you can throw together a make shift get up to get it out.Sears carries a 1/8" drill bit about 10 inches long.It allows your drill to clear the diff case so you can get a straight shot to the bolt.If you take a same thread size bolt and drill a hole through the center of it,you can use it as a guide to drill a hole in the stuck bolt.Then get a small extractor and twist it out.It's time consuming but you can get it pretty easy.Here's a visual. http://broncograveyard.com/bronco/i-...actor-kit.html
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It is also wise to take a small ball peen hammer and hit the carrier where the cross shaft pin passes through it. The hammering will cause a shock through the metal. And when trying to twist the pin out, will allow it to pop free without breaking.
If you need to drill to get the pin out, it is best to drill slightly at an angle. you can then slip a small philips head screw driver into the hole you made, and use it as a lever to spin the pin out of the cross shaft.