8.8 Rear End Axle Retainer Pin Stuck

[austinsnake]

Hello All,

I am working on swapping out 4-lug axles for 5-lug axles & disc brakes on my '87 8.8 rear end.
Pulled the diff cover off, removed the cross pin retainer bolt with no problem, and I am now trying to slide out the axle pin before removing the c-clips and sliding out the axles.
I have the axles pulled outward as far as possible, and the axle pin does have maybe 1/16" inches of play in either direction, so it's not totally in a bind, but it won't go out any further. I tapped on it gently with a hammer but it's somehow not wanting to budge and I don't want to give it a big whack if that might somehow make things worse.

The car is on my 2 post lift supported on the 4" main tubes with the axle hanging down. Wondering if that may somehow bind things up.

I raised up the pumpkin a bit with a tall jack stand to see if that might help, but no change.

Any suggestions?


Thanks,
Brian

[Papa]

Try this...


https://youtu.be/Ufc6h1G_Nt4?si=TleHha6QZo_C7h05

[austinsnake]

Thanks, Papa.

I used a jack stand under the pumpkin per the suggestion in the video, changing the angle of the drive shaft from a few degrees downward to parallel with the floor (all the rear end weight supported by the jack under the pumpkin), but with no change in results. The pin can still move slightly in either direction, so it's not in a bind, but will not go any further, even with a bit of hammering from either end.

When I push / pull the axles in / out (they move maybe 1/16" of an inch or less), I can see them touching / moving away from the pin, but there must be something else inside that the pin is getting stuck on.

Not sure what to try next.

[michael everson]

Did the whole bolt come out? I have heard of the pin on the end breaking off. Post a pic of the bolt. If thats ok, then there is really no reason for it not to come out.
Mike

[weendoggy]

If the lock pin is completely out (no broken parts as Mike said) it can hang on a small wear lip through the housing/case. Good persuasion is needed.

[rich grsc]

Broken retaining pin or you just aren't hitting hard enough. There is no reason to not really hit it

[austinsnake]

Thanks guys for the follow up.

It does indeed look like the retaining bolt sheared off and the end is still in there, when comparing it to a new one which I now see is much longer.
It came loose pretty easily with a short box end wrench, so I'm surprised that would break it. Perhaps a previous attempt by someone else sheared it off and the 'solution' was to just screw it back in :-)

224914

I guess from here I need to try and drill it out without damaging the threads. Perhaps removing the bearing cap to the right of it would clear enough space to get a drill bit in there.

Any other suggestions?

[Papa]

My go-to is almost always YouTube for stuff like this. Here is a video that might help:


https://youtu.be/YJCO4bb4G8o?si=DrpdEYu9P5Nh7LC-

[austinsnake]

Thanks, Papa.

Yes! YouTube is a lifesaver. i also found this similar solution of a guide bolt and long, flexible drill bit.

https://www.youtube.com/watch?v=gyu0otJxiwM

[michael everson]

try a magnet first. Then brake clean and super glue on the end of something round that fits loose in the hole
Mike

[AC Bill]

Maybe the last guy torqued the bolt to 15 ft/lbs, not 15 inch-pounds as required?

[austinsnake]

Success!

Using some of the ideas above...

I first tried vaccuming it out, hoping there were no threads left inside, but it didn't budge.

I then drilled through the original bolt with a 1/8" bit, and screwed it back in to use as a guide for further drilling.

224926

After a few failed attempts, I finally coerced the easy-out to stick in the hole with some firm whacks. I was then able to back it out by hand with a crescent wrench on the square end. That was a good feeling!

224927

The retaining pin slid out like butter as expected, and the c-clips and axles came right out.

Drum brake assemblies comes off next, and Richard Oben's disc brake setup goes on.

Thanks All for your very helpful feedback! This forum is an amazing resource.


Brian

[CraigS]

Excellent! Thx for reporting how you succeeded.

[Jeff Kleiner]

Good job! I had that happen once and didn't get so lucky :(

Jeff