The Stovebolt Site Forums The Shop Area Driveline 1959 1/2 ton rear axle stuck

Some Background Information: I had removed the rear end several years ago from the truck. Completely disassembled and painted the axle housing. Everything went to a speed shop where the gearing was replaced to a different ratio more suitable for highway driving and fuel economy. Speed shop rebuilt the rear end including new bearings and seals. When I got the rear end back I bolted it into the truck. The truck then went into storage for several years (10ish) while I was being transferred around Canada for work. When I got to a point where I was settling down and getting back to the build I had my dad tow the truck from mid western Ontario to northern Alberta. The truck was towed on a car dolly. The passenger side seal must have been damaged when installed as it leaked oil quite a bit. My father ensured it had plenty of oil and monitored the rear end to ensure it did not get hot.

Today I was inline for replacing the rear seal. Removed rear cover, pin and square block, just as I have on other trucks including the particular 59. Oil was good, clear and no metal in the bottom of the banjo. Smelled as it should. I needed to use a rubber mallet to push the axle in to get the c clip out. With the clip out I can only pry the axle outwards approximately 1/2” - 3/4” before it stops. Feels as though the c clip is still in even though it has been removed. Both small planetary gears are now out.... the axle will not move outwards enough for the splined gear to come off the axle splines..... I have not touched the bolts that hold the carrier...

Has anyone run into this issue. What am I missing?

Will the axle shaft on the other side come out? If so, remove that one and use a piece of pipe or a long steel bar inserted from the side with the missing axle to tap the sticky one out. You've probably got a burr somewhere that's keeping the spline from sliding out of the side gear. Don't get violent with it- - - -just give it a few firm taps with a BFH.
Jerry

Hy G-Town, welcome, if the clip is off the inner end of the axle there should be nothing to stop the axle coming out, there may be a burr in the axle spline that is hanging the axle up. Apply more force or push the axle back in and inspect for burrs and correct any you find, good luck.

Assume you have the wheel & brake drum off?

Wheels and brake drum removed. In fact all brake components have been removed. I plan on heading out to the garage to have another go at it shortly.

Axle is removed! Sometimes leaving and coming back to it I suppose. I was correct. The seal had been badly damaged during install it looks like. The bearing remained on the axle shaft and I fear it will need to be cut off and a new one installed prior to reassembly. Priced a new bearing from Napa... $120 each....