axle shaft stuck in differential

[240Joe]

83 300D 132kmiles


I just replaced my differential but I have one of the axles stuck in the old differential, and I can't get it out. I have tried prying every way possible. Anyone had this happen and what was the solution, if any.

My thinking is that the splines are damaged, so maybe it's not worth the effort because the shaft spline aren't good anyway.

thanks
Joe

[leathermang]

So, I am assuming that you pulled the clip off from inside ? Do you have the cover off the back side ? Greg

[240Joe]

Yes, I pulled the clips and the left side came right out. Let me bring you up to speed on what I did.

The car had a clunking while moving from drive to reverse, and even clunked pretty good while going 30 or 40 and apply throttle and let off.

I raised the rear left wheel and measured about 3.5 inche of play at the tread, way too much. Most of the play looked to be in the differential itself, not the flex plates. I compared it to my 1980 240D, and it has about 0.75 or 1 inch of play at the tread.

So I ordered and received a salvage yard differential, 3.07 ratio. During the teardown, I couldn't get the right axle off, so I just dropped the whole differential with the right axle. Like I said in the beginning, the left side slid right out.

After I got the cover off, I found the source of all the play. There is a pin in the center of the differential that rides in a hole. The hole was elongated, and the pin would move back and forth about 1/4 inch, which causes lots of slop at the wheel.

Anyway, I now have the new diff in, and the left axle in, and the fuel hose that I touched, and it sprung a leak fixed, but I can't get the right axle out of the old differential. I worked about 5 hours on it alone today, and moved it about 3/4 of an inch, but can't get it to move any more.

I'm thinking the splines must be trashed, so maybe any more effort on it is wasted, since the diff is toast and probably the axle splines are bad.

I'm wondering if anyone has seen this type of failure before. I've posted up on the tech portion of the site, but so far only one person tried to help, but he hadn't seen the problem personally.

Anyway, thanks for reading.

Joe

[84300DT]

joe -

you saw my reply about essentially the same problem on the tech
threads- my 1/2 shaft wasn't stuck to the diff as your rh side is but still had to be pounded out ie. bang the heck out of it to the right side from the inboard cv joint. In any case i went with 2 replacement rebuilt 1/2 shafts as both sides had damaged splines and lots of scoring on the ends.
likely if the rh 1/2 shaft is totally seized into to the old diff you will not be able/want to use it again- would suggest use it for the core price on a re-built one!

let us know how it turns out - good luck!

[240Joe]

84300dt

I think you're correct on getting a rebuild axle. The only problem is that I can't even get it off to use it as a core.

Thanks

Joe

[84300DT]

you might try soaking it with wd40 or the like and then taking
a sledge to it since further damage is not an issue.

[leathermang]

If you have the other side out... can't you use a metal rod to hit on from the outside ? So you are applying pressure exactly in the direction it needs to move..... Maybe it has worn a groove at the bearing which it is laying in enough to keep it from sliding out....

[240Joe]

You can't hit it from the other side because the round rod in the center is in the way. I couldn't figure out how to remove the center rod.

I soaked it with liquidwrench, WD40, regular motor oil, and a thorough dose of curse words, all to no avail.

You can't hit it with a sledgehammer because the center rod is in the way. I tried to get it out by using a very large screwdriver, and prying on the center rod. I was able to move it a little, but not very much.

If anyone knows how to get the center rod out, that would help because then I could hit it with a sledge and a drift from the other side.

I removed all of the bolts on the ring gear, but nothing came apart. I don't understand how you take the differential apart.

If anyone knows, please let me know.

thanks
Joe

[Ken300D]

I'm looking in a Parts Catalog and it appears the center shaft is held in place by a locking pin in one of the small gears at either end of this shaft.

I just had to do differential work on a GM product, and the center shaft was held in by a locking pin that was screwed in like a bolt. This one looks like it might be pressed in somehow. So watch the gears for a locking pin as you turn the assembly around.

I can't do the "wheel back and forth" test right now on my car because its up on ramps for a starter replacement (hopefully this weekend. )

The key to differential disassembly appears to be getting that little center shaft out.

Ken300D

[Fredmburgess]

Hey Joe,

I've got an extra axle and am sick of stepping over it. It's out of a 1980 240D with 210,000 miles on it. CV's are good, boots are ok. I've only had my '84 300D turbo for a few months and thought all that clunking during shifts was in the driveshaft or one of the axle, so I got these (have complete drive shaft too) from a junk yard. ...of course, then i learned all about vacuum leaks and shift modulators...duh!

So, want an axle so you can toss that other one? You can have it for $25 plus shipping. Just let me know. ...and no, I'm not telling you guys OR my wife what I paid for the darn thing even though I had to get it out!

Fred Burgess

email: fredmburgess@aol.com /or/ fredburgess@imtglobal.com

[84300DT]

I think Ken may be on to the solution - I think the rod he's referring to may have been the part busted on my old diff - but I kind of thought the rh axle shud come out if you just remove the horseshoe clip?

[leathermang]

240Joe, Sorry , I am having to use memory only because I loaned out all my manuals...

[240Joe]

I think I probably did something like you suggest, but I used 2 chisels. Unfortunately, it looks like it is going to damage the inner metal CV cover, so I stopped.

It is really in there, so I'm pretty certain that the splines have to be damaged.

Now the only reason to get it out is to use it as a core, so I guess trashing the cv cover is really not important.

thanks for the thought.

Joe

[Capt Kirk]

what you need is leverage.

Get a big Crowbar and hammer it into that 3/4" space you made.

then just start rocking the crow bar back and forth. You might need some one there to help tug at the halfshaft though.

BTW: You did remove the outter joint first right? (I assume you did since you were able to remove the other side)


Also it wouldn't hurt to give the inner CV joint a few good hits with a Ball-peen.

[leathermang]

Be sure and try pushing it out with the weight off the splines.... I think it may have worn a groove at the bearing that it is laying in... it should not take this much force to get that out otherwise... Greg