Well after looking around for a while I noticed there was quite a lot of threads on how to get the axle and birfield out of a front diff but there wasn't any real good examples of how to get the axle off the birfield so that it could be replaced. So here is how I do it in case it helps someone out
Jack the front up and remove the wheel.
Undo the 10mm headed bolts and remove the FWH switch.
Remove the 12mm acorn nuts and hit the studs with a soft face hammer or brass drift. This will remove the cone washers.
Dig around in the grease and remove the large external circlip
Once you have removed the circlip you can slide the rest of the FWH assembly off and get to the large nut inside. The large nut (55mm) has a tab lock washer holding it in place so remove this before you try to undo it. Once you have bent the tabs back undo the nut.
Then remove the tab washer and the inside nut. Then simply undo the calliper and slide the hub assembly off. Now you can undo the 14mm bolts and remove the front retaining ring.
Once you have these out tap the outside housing with a soft face hammer and it will come off. Depending on age you may need to give it some encouragement and as a last resort use a drift or small lever.
Now the Birfield and axle will be seen.
You simply line up the flat surfaces and pull it out.
Now you will see a circlip at the rear of the birfield near the inner CV cage. This is to stop the axle binding in the rear of the birfield and has nothing to do with retaining it. The birfield will now slide off the axle.
They are usually pretty keen to stay on there so you need to give it some encouragement.
It is quite a simple process but if you were not certain how to do it you may be concerned that damage may occur as you need to apply force to the back of the birfield. I have seen a few people using a hammer and a vice and a heap of hits. In my experience this is not the most effective way to remove the birfield and greatly increases the chance of damage to the axle splines.
The easiest way I have found is to place the axle into a length of pipe which is longer than the axle assembly itself. The ID of the pipe I use is around 35mm with a 2mm wall thickness. This sits just nicely over the circlip and against the rear of the inner CV cage. I also place a bit of rage inside the other end of the pipe so when the birfield comes off the axle does not drop onto the concrete and get damaged. Once you have it set up you simply drop the pipe onto a hard surface such as a piece of timber or concrete. You will usually find it comes out pretty easy and without damage.
If you find you need more force just drop it again from higher up or apply down force when you let it go.
Take one length of pipe (I paint it to mark it as a tool not scrape)
Stuff a rag in the end of it to protect the axle when it drops out of the brifield.
Then slide the axle assembly in the other end (note this picture is after I have separated it but shows the process. The circlip is usually snug against the Birfield)
Slide it all the way in and check to make sure the pipe is snug against the inner cv cage.
Then simply drop it on a hard surface. The axle will drop into the pipe and the birfield will be left in your hand.
The axle separated from the Birfield.
I hope this helps someone out, if you have any questions please feel free to ask. This is written as a guide not as a technical article. There are many ways to do stuff and this is just one of them.
Jack the front up and remove the wheel.
Undo the 10mm headed bolts and remove the FWH switch.
Remove the 12mm acorn nuts and hit the studs with a soft face hammer or brass drift. This will remove the cone washers.
Dig around in the grease and remove the large external circlip
Once you have removed the circlip you can slide the rest of the FWH assembly off and get to the large nut inside. The large nut (55mm) has a tab lock washer holding it in place so remove this before you try to undo it. Once you have bent the tabs back undo the nut.
Then remove the tab washer and the inside nut. Then simply undo the calliper and slide the hub assembly off. Now you can undo the 14mm bolts and remove the front retaining ring.
Once you have these out tap the outside housing with a soft face hammer and it will come off. Depending on age you may need to give it some encouragement and as a last resort use a drift or small lever.
Now the Birfield and axle will be seen.
You simply line up the flat surfaces and pull it out.
Now you will see a circlip at the rear of the birfield near the inner CV cage. This is to stop the axle binding in the rear of the birfield and has nothing to do with retaining it. The birfield will now slide off the axle.
They are usually pretty keen to stay on there so you need to give it some encouragement.
It is quite a simple process but if you were not certain how to do it you may be concerned that damage may occur as you need to apply force to the back of the birfield. I have seen a few people using a hammer and a vice and a heap of hits. In my experience this is not the most effective way to remove the birfield and greatly increases the chance of damage to the axle splines.
The easiest way I have found is to place the axle into a length of pipe which is longer than the axle assembly itself. The ID of the pipe I use is around 35mm with a 2mm wall thickness. This sits just nicely over the circlip and against the rear of the inner CV cage. I also place a bit of rage inside the other end of the pipe so when the birfield comes off the axle does not drop onto the concrete and get damaged. Once you have it set up you simply drop the pipe onto a hard surface such as a piece of timber or concrete. You will usually find it comes out pretty easy and without damage.
If you find you need more force just drop it again from higher up or apply down force when you let it go.
Take one length of pipe (I paint it to mark it as a tool not scrape)
Stuff a rag in the end of it to protect the axle when it drops out of the brifield.
Then slide the axle assembly in the other end (note this picture is after I have separated it but shows the process. The circlip is usually snug against the Birfield)
Slide it all the way in and check to make sure the pipe is snug against the inner cv cage.
Then simply drop it on a hard surface. The axle will drop into the pipe and the birfield will be left in your hand.
The axle separated from the Birfield.
I hope this helps someone out, if you have any questions please feel free to ask. This is written as a guide not as a technical article. There are many ways to do stuff and this is just one of them.
