12 bolt differential pinion shaft removal

[dmjlambert]

I want to remove the c-clips and pull out the axle shaft. This 12 bolt differential is giving me a hard time or I don't know what I'm doing. On my 1969 differential I removed the differential pinion shaft lock bolt and the pinion shaft fell out. On this 1963 one I was able to remove the lock bolt intact. But I can't get the pinion shaft to come out. I tried pushing it from both sides, and I tried using a socket and tapping on it with a hammer (lightly). It moves about 1/8 inch. It can rotate with the gears. What to do?

[dmjlambert]

http://www.youtube.com/watch?v=WfPleGYBbZY

Here I show what I'm trying. I removed the lock bolt, and tap on the shaft until it stops, then turn the gear 180 degrees and tap it back the other way. I think it is getting to have slightly more movement, but only barely detectable amount.

I have been thinking about putting the cover back on, and filling the case with vinegar and rolling with it for a dozen miles, to dissolve rust. But the truck is not yet running so I'd have to hook up a tow bar and disconnect the drive shaft and pull it, which sounds like a lot of trouble. Another thing I've been thinking about is putting the lock bolt back in, turning it to the side that doesn't have the lock pin, and drilling and tapping a hole and perhaps use a slide hammer to get it out.

[bigmoe]

It's been a while since I did mine but I don't remember having any difficulty removing the pinion pin once the pin bolt was removed. Maybe a little more persuasion? Don't let those pinion gears fall out. To clean it I'd just hand remove as much sludge as possible and then hit it with some solvent.

[Mike C]

Extremely worn differentials often have the shaft cut into by the spider gears. These require pretty significant hit to move. I use a drive and try and drive it as far as I can out the other side of the case and have the differential where it will still rotate. Then when it’s facing you grab it with a big pair of vise grips and wiggle if it doesn’t come out.