Tools you'll likely need:
* Jack and jack stands: To safely lift the van.
* Wheel chocks: To secure the van's wheels.
* Lug wrench: To remove the wheel.
* Socket set and ratchet: Various sizes will be needed.
* Hammer: A ball-peen hammer might be useful.
* Pry bar: May be needed to help break things loose.
* Penetrating oil (like PB Blaster): Essential for loosening rusted or seized components.
* Torque wrench: Crucial for proper reassembly.
* C-clamp (possibly): To compress the axle flange.
* Axle nut socket (usually a large size): This will often be a special socket.
* Drain pan: To catch any fluid that might spill.
Steps (General Procedure):
1. Safety First: Park the van on a level surface, engage the parking brake, and chock the wheels. Lift the van safely using a jack and secure it with jack stands.
2. Remove the Wheel: Remove the wheel and tire assembly.
3. Disconnect Brake Caliper: Remove the brake caliper and hang it safely out of the way using a wire or bungee cord. You may need to use a C-clamp to compress the caliper piston to avoid spilling brake fluid. *Remember to replace the brake fluid if necessary.*
4. Disconnect ABS Sensor (if applicable): If your van has an anti-lock braking system (ABS), carefully disconnect the ABS sensor from the axle.
5. Remove the Axle Nut: This is often a very large nut. Use penetrating oil liberally and let it soak for some time before attempting to remove the nut. You may need a breaker bar for this step.
6. Remove the Axle Flange: Once the nut is removed, the axle flange may still be stuck on the axle shaft due to rust or corrosion. Use a hammer and a punch (or pry bar carefully) to gently tap the flange free. Be careful not to damage the axle shaft or surrounding components. A puller tool designed for this job might be helpful, but not strictly necessary. A press may be needed for some circumstances.
7. Remove the Axle Shaft: With the flange removed, the axle shaft should slide out of the differential. You may need to gently tap it out with a hammer and a soft-faced mallet or block of wood.
8. Installation (Reverse Order): Installation is the reverse of the removal process. Remember to torque all bolts and nuts to the manufacturer's specifications (found in your repair manual). You'll likely need a new axle nut unless you've managed to save it undamaged.
Important Considerations:
* Differential Fluid: You might lose some differential fluid during this process. Be prepared to top it off or replace it completely.
* CV Joint: If the axle shaft has a CV joint (common in front-wheel-drive applications, but less common in full-size vans which are more often rear-wheel-drive), take extra care not to damage the CV joint boots. Damaged boots can lead to significant repairs later.
* Rust and Corrosion: Older vehicles are more prone to rust. Use penetrating oil liberally and work patiently to avoid damage.
This is a complex repair job. If you're not comfortable working on your vehicle, it's best to take it to a qualified mechanic. Improperly installing the axle shaft can lead to serious safety issues. Always consult a repair manual specific to your year and model for detailed instructions and torque specifications.
