I have a 1995 Ranger W/7.5 rear end.
side gears broken. bought new gears: inner axel gears, side gears and that 1" pin along with the carrier pinion locking bolt.
I cannot get the little gears w/ the thrust washer to fit. The axel gears with their thrust washers installed fine, but when I line it all up and rotate it this way and that way they hang up. Any speical trick to this?

 

Generally you rotate one axle (or side gear) and not the other and you can get the gear to move into where you can put the pin in. Do one, secure it with the pin, then do the other.

However, I've only worked with 8.8's and Dana axles, so maybe something is different in the 7.5.

One other thing I though of: is your carrier bent or damaged? If the gears got chewed up, that could have been a bit of stress on it.

 

Thanks,
I can get the gears to line up with the carrier hole, but am having a heck of a time getting those thrust washers to go with them. they are the cupped ones.
i had to stop for now, so to make me feel better, I am going to fry up a pile of Razor Clams.

 

Ha ha! Enjoy.

Did you lube everything? I had to use a bit of oil on my Dana diff when I was assembling it or things kind of stuck. Maybe that's a dumb question as everything is coated with oil already. But my diff I had parts washed and the gears came from another carrier I had with less wear on the gears so I had to put it all together and everything was dry and that didn't work well.

Can you put the washers in first, then slide the gears in over them? Maybe with the washer held in place by something through the hole for the pin?

 

I gave it another go and found that I had one flat thrust washer on the axel side to many. One of the pinion thrust washers cracked, so will have to wait until after the holiday to get another. Thanks for the info.
BTW, Razors were awesome. flash fried. 400 degrees for 20 seconds.