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Old 05-09-2002, 10:16 PM
240Joe's Avatar
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Join Date: Nov 2000
Posts: 525
Axle shaft stuck in differential - how to remove?

I finally got the differential out of my 83 300D, but I had to remove it with the right side halfshaft in the differential. I still can't get the axle out. Any ideas? I don't know if the splines are damaged or what?

thanks for any help

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Old 05-09-2002, 11:13 PM
Senior Member
Join Date: Apr 2001
Location: Baton Rouge
Posts: 485
You have to remove the cover on the diff housing there is a clip holding the axle in.
euro 287
Mercedes Technician 7 Years (retired to Hyundai)
2000 Dodge Durango
98 Mazda truck
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Old 05-10-2002, 07:38 AM
240Joe's Avatar
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Posts: 525
I already took the clip out. It is still stuck.
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Old 05-10-2002, 08:22 AM
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Join Date: Aug 2001
Location: Northern Virginia
Posts: 2,911
It's usually pretty hard for the splines to get stuck because they are normally splashed/bathed in gear oil. If I remember correctly you had some differential damage, so you might have some metal shavings in there jamming the splines.

If you don't care about the axle shafts, you might loosen the splines with some hammer blows on the end of the axle shaft. This might force the axle in a little bit and result in it being loosened.

If you are trying to reuse the axle shafts, maybe you can come up with a "pusher" to push out the shaft from the inside of the differential case. I'm thinking of something like a threaded rod cut to just the right length, and then a threaded coupler that has been threaded onto it. You hold the bolt in position and then turn out the coupler. This will give you a lot more force than you could create with your hands. I'd put the turning coupler against the axle shaft, because if you scratch that end it doesn't matter much.

Since you have the whole assembly down, if it were mine I'd go ahead and replace all the oil seals too - the pinion seal on the front and the two axle seals.

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Old 05-10-2002, 01:45 PM
240Joe's Avatar
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Join Date: Nov 2000
Posts: 525
There's not enough room to make any kind of bolt/nut pusher. It's completely frozen in. I've worked on it for 3 hours now and it's moved maybe 1/16 inch out.

Any other ideas, anyone???

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