Anyone rebuilt front/back differential on 3.0 pre facelift?
 

Slowly chipping away at putting my X5 back together, piece by piece.
I had taken everything apart to change all the bearings, balljoints, bushings, suspension etc.

While I had rear diff out, I thought I'd repaint it.
Blocked the sides where halfshafts go in and tried stripping the paint, no luck.

Eventually decided to try sandblasting with aluminum oxide. Worked pretty well, but I guess it was a bad idea, now when I turn the flange at the front, I can hear the noise of the sand...somehow it got inside.
Maybe it's a stupid mistake, it's my first time sandblasting...

I'm thinking of opening the differential to clean aluminum oxide from inside. But I know the differential has to be pre-loaded or it won't last long.

So if anyone has rebuild a differential, any clue where to buy the crush sleeve? I can't seem to find them anywhere...

The other option is to finish sandblasting, paint it and then use some old oil to refill and drain it a few times, hoping all the aluminum oxide will wash out.

What a stupid predicament I've gotten myself into lol!

Just get a used diff to replace it. The crush sleeve should be available but you could shim it and/or use some red loctite on the pinion nut in a pinch but I think you are just going to get yourself into more trouble.

There is no reason to go through that effort to get the old paint off in the first place.

I found a couple of posts of people replacing both front and back diff crush sleeves.
There's pretty much no doubt that the part number is 33121200259

But I don't think I actually have to worry about it.
I'll finish sandblasting it, then I'll powdercoat it and then I'll just remove the real plate to take it apart and clean it.
I guess I don't actually have to remove the crush sleeve ar all.

Diff seals will not protect against blasting. You can blast an empty case.

My observation from the couple of times I've had a friend to it against my advice is that the diff is trash. Pick up used ones from a salvage yard.

Thanks for your advise.
I'll try to wash out the aluminum oxide from inside and see what happens.
I'll post the results here.
I'm wondering now if the front seal behind the flange would withstand powdercoating temperature or would it get damaged?

I think I found a better part number!

This one seems to be the right one for sure!

31521211090

I mean, it's not good for it. And the diff is trash anyway. So why not see?

I can just remove the rear plate of the differential, take it apart, clean it, and put it back together without needed to remove the front nut/flange/seal