Differential

 

        Instead of following the standard build order, I decided to install the rear differential and propshaft before I installed the engine and transmission.  The first step was to bolt the bottom of the differential onto the frame.  To do this, I used the jack to lift it up and hold it steady while I stuck the bolts through and screwed them in.  To insert the spacing washers, I tried a number of different combinations of washer sizes until there was no gap between the frame and differential.  I used a flat head screwdriver through the bolt hole to align the washers before inserting the bolts.  

Now that the bottom bolts were on, I swung the diff up and got ready to put the top bolt through.  One side the frame was not aligning well with the differential, so I used the other side to start the bolt.  Again I tried different combinations of washers until it was tight.  After getting the bolt in on one side, I needed to get it out the other.  But the hole in the differential was still not aligning with the frame.  I fixed this by using the jack to move the differential around.  After encouraging the bolt with a mallet and ratchet, I finally got it through.  I torqued everything to spec.

Now it was time to install the propshaft.  After attempting to slide the prop shaft into place through the transmission tunnel, I realized I had a major problem.  The only way the propshaft would fit in was through the opening now covered by the differential.  There was no way around this.  So I untightened everything and pulled the upper differential bolt off.  By swinging the differential down, I was able to get enough room to slide the prop shaft through and into the gap.  I then re-installed the bolt using the same method and tightening everything to spec.  Again.  Then I installed the 4 bolts that held the propshaft to the differential.