Hello!

I am looking for some help with my new to me 2002 gmc jimmy with the 7.625 rear end.

i am replacing axle bearings and have experience every obstacle possible with this thing. Stripped fill plug/ sheared cross pin just after the threads. I welded a bolt to the plug and used 1/4” line connected to my vacuum to suck out the rest of the pin. (Pictured)
the pinion shaft was also hard to remove as it was wearing into the gear and the hole for the pin is slightly ovaled. I think I will replace this.
A

Sheared cross pin

How I removed the sheared pin

Oval

Worn grooves

Washer/spacer?

Different sides of same washer
fter bearings/seals where done and I was installing the c clips on the axles I noticed a cone shaped washer sitting at the bottom of the diff. I don’t think it was there before but I can’t find anywhere it would go.
i was extremely careful with the spider gears and slidding in the axles so I am very confused where this goes.

appreciate anyone’s input and thanks for reading.

 

That "washer" goes behind one of the planetary spider gears. There is one behind each gear.

 

Holy Moses Batman how the H did that solid steel pin get broken?

Im guessing the diff carrier may need replacing with that much abuse, with metal fragments in the diff, its likely the diff bearings are damaged.