Engine/Transmission (1998.5 - 2002) FUBAR'd & out of ideas, can't remove front diff. or intermediate axle shaft on 01.5

[Coalsmoke]

Ok, here's the problem I'm having. Doing the front end on my new project, replacing everything that moves and is showing any appreciable sign of wear. The truck is the 01. 5 in sig. The front axle seals are just starting to weep, so I figure since its all apart, I'll do them now. Its not the first time I've done axle seals, but I've never done fronts on an 01. 5 before, not with problems like this at least.



Both hubs off and both of the outboard axle shafts are out, no problems there, but I can't get the intermediate axle shaft out. The CAD collar is a lot wider than what I'm used to, and I can't snake it out of the CAD access port with the intermediate axle shaft still in there, simply is not enough room. The CAD collars I am used to have a beveled side and a flattened side, this one has a bevel on both sides and is wider.



To make things worse, I can't slide the intermediate axle shaft into and through the cad collar which would pull the shaft out of the diff enough to drop it, because instead of it necking down after the splines for the CAD collar, the splines are actually cut into a larger OD shaft, and I can't get the diff out with the intermediate axle shaft still stuck in there.



Soo... ...



I figured great, I have either some mix mash of parts that Dodge was using up at the factory when they were phasing out the CAD system, as the truck's build date is 2001 - 05 and I think they phased out the CAD in the last half of 2001 build date. Or, I someone has some beefed up aftermarket parts in here, lord knows how they got them in if that is the case. So, figured if I could get the cross pin and spiders out of the carrier I could maybe buy myself some wiggle room and maybe with the intermediate shaft half out of the diff and the spiders out I could slide the carrier out, but, the problem is it feels like the roll pin is welded in. I can just snake a punch in there but that roll pin is NOT moving. I even have the luxury of breaking off a punch in there, so now I have something to keep me occupied for the next couple hours trying to get that piece out. So, anyone have any ideas? Anyone heard of this before? I never saw this when working at the stealership, so I don't think its too common.



I'd rather not have to torch out my carrier, seems a little drastic for a couple of seals and I don't have the money for an ARB up there.

 

[Coalsmoke]

Got the broken punch out. I'm considering the idea that this axle may have a manufacturing flaw in it. If anyone is reading with a 2000-2002 and wouldn't mind taking a couple of measurements, I'd appreciate comparing some notes. On the passenger / right side of the differential, I have 5 3/8" from the edge of the cast diff housing to the inboard edge of the cad cast housing, and 2 1/8" from the outboard edge of the CAD housing to the inside edge of the spring mount. These measurements are taken from the center backside of the axle housing. Thanks in advance.

 

[SnoKing]

Got the broken punch out. I'm considering the idea that this axle may have a manufacturing flaw in it. If anyone is reading with a 2000-2002 and wouldn't mind taking a couple of measurements, I'd appreciate comparing some notes. On the passenger / right side of the differential, I have 5 3/8" from the edge of the cast diff housing to the inboard edge of the cad cast housing, and 2 1/8" from the outboard edge of the CAD housing to the inside edge of the spring mount. These measurements are taken from the center backside of the axle housing. Thanks in advance.

I can take some measements tomorrow morning for you. I have a May 2001 build 2500 auto standard cab with the cad. SNOKING

 

[Coalsmoke]

Thanks Snoking, I'd really appreciate it. I'm worried that the this is a replacement axle (evidence of it and the diff being out) and that I may have the wrong shafts for the housing, like someone took a late 90's housing and stuck 01 shafts in it, or vise versa.

 

[SnoKing]

Got the broken punch out. I'm considering the idea that this axle may have a manufacturing flaw in it. If anyone is reading with a 2000-2002 and wouldn't mind taking a couple of measurements, I'd appreciate comparing some notes. On the passenger / right side of the differential, I have 5 3/8" from the edge of the cast diff housing to the inboard edge of the cad cast housing, and 2 1/8" from the outboard edge of the CAD housing to the inside edge of the spring mount. These measurements are taken from the center backside of the axle housing. Thanks in advance.

Measurements are the same on mine! I have my service manuals with me, if you want me to look up anything for you. SNOKING

 

[GHarman]

Moral Support

Coalsmoke, Reading your posts. Sorry you are having such a headache with your front axle! GregH

 

[Coalsmoke]

Thanks Snoking for checking, and Greg for the thoughts, I appreciate it. I have the service manual too, and they say nothing out of the ordinary for removing the diff. Of course, this is the same manual that forgets to mention that the diff must be pulled to do the axle seals. I can't figure this one out, the axle housing is obviously correct, the shafts should be correct as they are the 32 spline, which if I remember is that oddball set of shafts used only for a couple of years in these later 24 valves. I guess I'm going to have to get creative.

 

[24Vpirate]

i dont know why your haveing such a hard time. no such thing as HD aftermarket part for the cad. you have to be doing something not right. just slide the collar to the right and tip it out of the cad. the roll pin must be punched from the ring gear side towards the non ring gear side 3/16 punch should be perfect. but that wont help. you can call me at my differential shop at 916-852-7109

 

[Coalsmoke]

Ok, just an update here, there was either a casting flaw or someone in the past has boogered up the bore for the roll pin retainer. I managed to clean it up with a drill and get the pin out, along with the spider gears. Problem is it didn't buy me enough wiggle room. I'm officially stumped on how this was even put together. The intermediate axle cannot be slid into the differential because it runs into the CAD bearing, and it can't be slid out of the diff enough to clear it because the CAD collar is larger than the axle casting that holds the axle seal, and the CAD collar does not slide over the splines in the intermediate axle due to the way it was designed, so leaving it in place and pulling the axle shaft out through the axle tube is out as well.

 

[Coalsmoke]

24V, just saw your post after posting my last post. My mind keeps going through the process of what am I missing, but I honestly can't think of anything. This is not really a technical job as far as jobs go. What is even more baffling is how were these components assembled in the first place?

 

[Coalsmoke]

Update: spoke with 24V on the phone and we figured pictures might be of some help.



Picture one showing cad collar not being able to slide over the splines and picture two showing double flanged cad collar without room to pull it out. Looks like the axle should slide towards the diff more don't it? I've had a pry bar in there and no luck, feels like it is snubbing into the bearing/bushing.

 

[Coalsmoke]

Well, got it figured out. Thanks to 24V for the phone help. Turns out a small piece of metal debris (probably from the removal of the last seal by the previous owner) had found its way in the cad housing. It was lodged in one of the oiling grooves in the bushing on the far side of the axle shaft, so it was impossible to see. Every time I would try to slide the axle shaft towards the diff it would stop 1/4" shy, and would feel like the shaft was snubbing up in the bearing, turns out it was that little piece of debris that was caught up in there and was acting as a wedge. Now that I've got the pieces out we can move the axle status from FUBAR to SNAFU :-laf If only that little shard of metal had picked one of the oiling grooves on this side of the axle I'd have been able to see it right off the bat. 24V asked if I'd tried to move the shaft with a pry bar, which I had, but it got me thinking, somethings got to give, those bushings are not too much money. The intention was to drive the shaft and bushing through the axle tube into the diff side. So I got a BFH and a long drift and working through the axle tube I was able to drive the shaft back enough by force that the cad collar had room to clear, and once I pulled the shaft out that piece of metal came out of the bushing as if it were sticking its tongue out at me. Ironically the bushing is none the worse for wear.