Tools You'll Likely Need:
* Socket Set: Various sizes, including metric and possibly SAE.
* Wrench Set: Again, metric and SAE.
* Hammer: A ball-peen hammer is ideal.
* Pry Bar: To help break things loose.
* Diff Seal Installer/Remover: To help with the seal removal and installation without damage.
* Penetrating Oil (PB Blaster or similar): Soak the bolts and shaft generously before attempting removal.
* Torque Wrench: Essential for proper reassembly.
* Wheel Chocks: Safety first!
* Jack and Jack Stands: To safely lift the vehicle.
* Drain Pan: To collect differential fluid.
* Front Differential Removal Tool: Possibly required for easier removal. This will depend on your axle design and whether you have to pull the whole diff.
* New Stub Shaft Seal(s): Don't forget these!
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels. Disconnect the negative battery terminal.
2. Drain the Differential Fluid: Remove the drain plug from the bottom of the differential housing. Let it drain completely into a suitable container.
3. Remove the Axle Shaft Nut: This is usually a very large nut on the end of the stub shaft. You'll likely need a breaker bar or impact wrench to remove it. This is often VERY tight. Penetrating oil is your friend here.
4. Remove the Axle Shaft: Once the nut is off, try to pull the axle shaft out. It might be stubborn. If necessary, gently tap the end of the shaft (near the wheel hub) with a hammer to help it loosen. A slide hammer or puller might be helpful here. Some models require removing the entire differential or at least the knuckle assembly. Consult your repair manual.
5. Remove the Seal: Once the shaft is out, you will need to carefully remove the seal from the differential housing. A seal puller is highly recommended.
6. Inspect Components: Inspect the differential for any other damage while the shaft is out.
7. Install New Seal: Install the new seal using the correct tool, ensuring it's seated properly. Improper installation will result in leaks.
8. Install New Stub Shaft: Install the new stub shaft, ensuring it slides in smoothly and evenly.
9. Install the Axle Nut: Tighten the axle nut to the manufacturer's specified torque. This is critical for the proper operation and longevity of your axle.
10. Refill the Differential: Use the correct type and amount of differential fluid specified in your owner's manual or a repair manual.
11. Reinstall: Reinstall all components, tightening everything to the correct torque specifications. Consult your repair manual for exact procedures and torques.
Important Considerations:
* ABS Sensor: If your vehicle has an ABS sensor on the axle, you'll need to disconnect it before removing the axle shaft and reconnect it after installation.
* Wheel Hub: Depending on your vehicle, you might need to remove the wheel hub assembly to get access for axle removal.
* Differential Removal: As mentioned above, some models require partial or full differential removal. This significantly increases the complexity of the job.
* Repair Manual: This is absolutely crucial for this job. The steps above are general; your specific vehicle may require different procedures and torque specifications.
This is a complex repair. If you're not comfortable working on vehicles, it's best to take your truck to a qualified mechanic. Improperly done, this repair can lead to serious damage and safety hazards.
