Hi Fred,
If the washers are available I always put them back in place. They do help
keep the vibration down, especially on worn differentials. The trick I use
is to put the first one on the long differential bolt as it slides thru the
bushings. The second washer is always the toughest and trickiest. It's not
too bad if you have the body off the frame and are reinstalling everything.
If you are trying to do it from underneath the car I would cut a small
section (3/8")out of the rubber washer so it can be pushed around the already
installed bolt (wait to torque the nut until after both washers are in
place). You could also try freezing the rubber washer and then applying
liquid dishwashing detergent (e.g., Joy, Dove, etc.) before you push it into
place. Try to pry the differential case away from the side where you will
install the second washer.
Bill Brockschmidt
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