80 series front axle shaft stu

[OLDSRIP]

hi all.

I am doing a Birf replacement on my 94 80 series.

The problem I am having is the front left axle shaft.( the long side)
Won't pull out far enough to put the clip on the outer end of the axle shaft.

I have gone so far as to pull the outer hub and backing plate, etc. off.
And now I can't remove the axle shaft. It has almost no in or out movement.
It acts like it's stuck in the diff.

When I installed the shaft it felt like it went in a long way, deeper than I expected.

Is it possible to have the inner axle splines seat to deep?

This is a locked axle and I had the axle locked when I removed and installed the shafts.

I can't figure out what is going on. Any ideas?

Thank you.

Joe W.

 

[ajax1]

Put screw into the shaft end and pull

 

[OLDSRIP]

Some more info.

before I tore it down to the knuckle. The axle shaft wouldn't pull out far enough for the clip on the outer end of the axle.

It needs to come out about 2 x the thickness of the clip. (Yes, I have the bolt in the end of the axle shaft to pull on)

Now I am looking at the open knuckle. The new Birf is a terreain tamer unit sourced from a popular mud vendor..

I can not get the shaft to pull out at all. ( the pass. Side is sliding in and out fine)

I can't see how it can be stuck. No excessive force was used installing it. It took a few tries and turns of the drive shaft before it slid in. But when it did it slid right in. And further than I thought it would, like I mentioned above.

I have been turning the driveshaft and retrying to pull the shaft out.
I'm not sure where to go from here.

Any suggestions????

Fwiw, I have done this job on Toyota mini trucks before. But first time on my 80.


Thanks again,

 

[OLDSRIP]

hi Ajax,

Thanks for the reply.

I have tried that. I'm not getting any in or out movement when I pulling on the axle shaft, even with it disassembled.
It's stuck???

Thanks,

Joe W


Very strange.

 

[Golgo13]

Is it the correct size Birf/Drive Flange combination?

Might want to check with your part source for more information.

 

[OLDSRIP]

Hi Golgo13,

Thanks,

I have a email into him now to see what he says.

But I think the problem is that the axle shaft is somehow stuck. I'm not getting any free play. If I had the same free play as I do on the pass side. I think I would be alright on the clip end.

Because even if the Birf was wrong somehow. I don't see how it could be causing the shaft to not come out of the housing.

The wrong Birf could cause the problem with the outer clip I imagine.

But right now I need to pull the shaft out of the axle housing.

However, I have been wrong before.

So keep the suggestions coming. I'm stumped today. And it's to hot.

Thanks,
Joe W.

 

[ajax1]

Line up the flats and still won't pull out correct? My next question would be is it the right length shaft then what year is your truck do you have the shorter flanges or the longer ones? You will need the correct bird length for the correct flanges

 

[ajax1]

Does the birf rotate around inside the knuckle ball? Maybe birf is slightly bigger causing it to hang up in the ball and you need to grind down the ball a little bit, if that is the case would been pretty tough to go in

 

[OLDSRIP]

Hi Ajax1,

Line up the flats and still won't pull out correct? My next question would be is it the right length shaft then what year is your truck do you have the shorter flanges or the longer ones? You will need the correct bird length for the correct flanges

Correct, lining up the flats still doesn't pull out.

It is the same shaft that came out.

My truck is a 94. According to the part listing it is the correct flange for the production date.

Fwiw, the right side slides in and out fine.

 

[ajax1]

idk man never heard of it going to deep maybe locker collar is hung up ? Maybe take the knuckle off and try pulling it out the birfield can rotate ?

 

[ajax1]

so new birfield but same shaft then

 

[ajax1]

Did you put all shims back in? Maybe birfield is at odd angle and you need up or down pressure while pulling

 

[OLDSRIP]

Does the birf rotate around inside the knuckle ball? Maybe birf is slightly bigger causing it to hang up in the ball and you need to grind down the ball a little bit, if that is the case would been pretty tough to go in

The Birf does rotate around inside the knuckle.

i did a visual inspection between the old and new parts and didn't notice anything different. But I didn't measure anything.

It's strange. I dont know what I'm missing. It should slide out easy now. But there is very little movement in or out while pulling/pushing on the axle.

There is plenty of free play on the right side.

Can I take the right shaft out and push that axle shaft out from the back side with out causing damage?

I can try a slide hammer on the outer axle Birf end also.

I hate forcing stuff that shouldn't have to be forced.

Thanks for your help

joe W

 

[OLDSRIP]

so new birfield but same shaft then

Yes sir.

 

[OLDSRIP]

Did you put all shims back in? Maybe birfield is at odd angle and you need up or down pressure while pulling

Are you referring to the upper trunion shims?

Yes, I kept all that together and made sure it went on the correct side.

Didn't see any other shims


I will try pressure at different points to see if it makes a difference. But was trying to lift and push and pull by hand today.

Thanks,
Joe W

 

[OLDSRIP]

idk man never heard of it going to deep maybe locker collar is hung up ? Maybe take the knuckle off and try pulling it out the birfield can rotate ?

Missed this one.

I was thinking of taking the knuckle housing off to see if that helps.
That will give me better access.

Yes, I can turn the axle. I did it to line up the flats. Plus I was rotating drive shaft.
Everything seems to turn normal.

It does feel like it's being held in at the diff end. But I don't know for sure.

I need to look for a good pic of the lock collar tomorrow.

I did manually engage and disengage the locker to see if it helped. But the free play remained the same.
(I have the locker actuator out on the bench refueling magnets)

Thanks,
Joe W

 

[ajax1]

Did you put the birfield to shaft back in right the clip inside the birfield fully seated? Got the star in right direction? Abs sensor is pulled out of the knuckle also correct?

 

[ajax1]

Or put it back together go drive it it can't go anywhere just because the c clip isn't on see if that frees it up

 

[bloc]

ABS sensor in the way? It'll prevent removing the birf from the knuckle.

If Terrain tamer sent you birfs for a 91-93 they are shorter than needed for 93.5-97. The later trucks had a thicker drive flange.

Did the clip go on the other side OK?

 

[OLDSRIP]

Did you put the birfield to shaft back in right the clip inside the birfield fully seated? Got the star in right direction? Abs sensor is pulled out of the knuckle also correct?

Good morning.

The clip seemed to seat properly. I used the clamp method.

I packed it as it came. I didn't disassemble the star.
The abs sensor isn't installed.

Thanks,

Joe W