Is there another ring out past that first one in the picture, right on the end or something that is preventing that CV Axle from coming off that smaller shaft with the splines (what I called a differential stub shaft above)? I am so close to getting it off of there but it just won't go that last 1/4 inch or so, very frustrating.

I think I read in the forums somewhere that Autozone or Advance Auto allows you to borrow a slide hammer (with a deposit), so I may give that a try. Are you saying to use the hammer for the CV Axle or that stub shaft--I think what I read in other posts is that people were using it for the stub shaft. If that is the case I will give that a try, I just need to get the damn CV Axle off of it first. Pulling with hands, using pry bars, and a 5lb hammer could not get the CV Axle off though.

Thanks again for your insight, much appreciated.

 

Yes the stub shaft. Make sure you replace that seal.

 

I am beginning to believe that it is not possible to remove that shaft. I have a slide hammer--I even borrowed a 4WD Spindle puller from AutoZone. The 4WD spindle puller does not attach to the shaft so I am now using a 3/32 7x7 galvanized cable attached to the slide hammer. I have hammered until my hands and arms hurt to no avail. I even ended up snapping the cable at one point and the shaft is still in there.

As far as the seal, i have seen in many other videos that there is a seal that bolts in over the shaft. I don't have anything like that, nowhere to bolt anything. I am hoping the seal--if there is actually one--will come out when/if the shaft comes out.

Is there anything else to try, for now my arms are tired and my hands hurt like hell from slamming the hammer. I cannot get that damn thing out of there for anything. I am getting desperate at this point




galvanized cable snapped after hammering, but shaft stayed put.

 

I took the differential cover off and figured i would remove the clip by reaching up between the spider gears. I now cannot seem to get the center pin of the spider gears out. There is supposed to be a small screw holding that center pin in but where the screw is supposed to be is an empty hole. Not good, but should allow me to slide that center pin. Well, it doesn't move at all. I have no idea why it doesn't move since the screw to hold it in place is missing but it doesn't move. I feel like I am running into a wall every direction I go. Does anyone have any ideas?




diff cover removed. gears turned so screw hold holding pin in place is visible. However, screw is not there....

 

It was a roll pin (spring pin). Used a punch from the back side (side facing passenger wheel) and got it out. Once out, was able to get the center pin out and the spring wire off and the shaft came right out.

Now to start putting everything back together.

Note: do your best not to let the spider gears fall out, they are a huge pain to put back in.

 

I thought I would give one final update now that everything is back together and the truck is running click-free. I also wanted to thank P38251 for the help.

Because the intermediate shaft would not come out of the differential after lots of pulling and snapping cables, I had to open the differential, remove the center pin (after removing the roll pin locking it in place, see pic in previous post), push the shaft into the differential, use needle nose pliers to remove the ring on the shaft, and then finally pull the ring free of the differential.

After that it was pretty easy stuff. I pulled the old shaft seal off with a pry bar and vice grips. Slid the new intermediate shaft in (make sure it goes all the way, it will stop short and a good push--or tap with rubber mallet--will get it in the rest of the way, past the snap ring) and put the new seal on over the shaft, which I got into place with the help of a small block of wood and a mallet--it is a really tight fit with that seal. Then it was just a matter of pushing the new CV axle onto the new shaft, compressing everything and putting the other end into the hub. It all fit nicely back together (I did have a little trouble at first but realized the intermediate shaft wasn't in all the way so I used the rubber mallet to tap it in--maybe I am weak but it didn't want to just push in) in the end. Replace axle nut, tighten to spec (i believe 185 ft/lbs), replace tire, lug nuts (tighten to spec), and put the little Ram cover back over the Axle nut opening.

At this point I filled the differential. It probably ended up being a good thing that I had to open the differential because the oil seemed pretty dirty. I filled it with 75w90 full synthetic oil after cleaning it out (and putting the damn spider gears back together--that was a pain). The day before, I sealed it with the black RTV gasket maker and let it sit for 24hrs before actually putting in the new oil. It took about 1 and 2/3 quarts before starting to come back out the fill opening. Once it started coming back out, I plugged the hole.

After getting it back together I fired it up and listened for any ticking. To my somewhat surprise, the ticking was gone. 2wd and 4wd seemed to work just fine. I only put about 10 miles on the truck since putting it back together but I am hopeful the repair will last me a while.

Thanks again for the help and information. Hopefully something in here will help someone else at some point.