I am in the middle of replacing the 2.2 gear set in the 8 1/4 rear axle in my brother's Duster. We got the axle all stripped down except the pinion is absolutely stuck in the housing. The nut is off and we were whacking it with a hammer, then a bigger hammer, then a 12 pound sledgehammer and it just isn't budging.

Anybody have any suggestions on how to get a stuck pinion out of an 8 1/4 housing still installed on the car?

Thanks.

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Casually looking for a Clifford hyperpak intake for cheap.

Sounds like the front pinion bearing has seized onto the pinion shaft...
It is time to remove the housing from the vehicle so you can "get serious" with the "hits".
DD

Ugh. I should have guessed as much. Thanks Doc.

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Casually looking for a Clifford hyperpak intake for cheap.

If you w ere closer I would sell you my 2.73 8 1/4" rear. Good luck.

Sam

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I wounder if using a propane or mapp torch would help?


or if you dont plan on using the pinion on the reinstall... an oxy acelytine torch.

Careful of the fuel tank!
Heatin & beatin... that how I get seized slides outta trumpets and Horns etc.

I have a 20 ton Press in the basement for such projects.. you are welcome to use it. It comes in quite handy for suspension and Gear work, for straignting the occasional bumper or header flange


Greg

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Thanks. I have a 5 ton press, I just can't figure out how to fit it under the car and around the axle.

I am not re-using the 2.2 gear ration pinion. I will try and beat the pinion out with a smaller sledgehammer that I can get more swing with under the car.

It is somewhat funny that normally "get a bigger hammer" is the punchline to a joke but in this case it is the correct way to solve the problem.

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Casually looking for a Clifford hyperpak intake for cheap.

Can you get your buddy to pull (somehow) from the other side at the same time? (hooked bar, 90 degree pliers, even a coat hanger wrapped around the gear)

A lot of the hammer force can be dissipated if the outer bearing isn't tight against the race as the pinion is struck.

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"A mechanic is Somebody."
- Jim Preston

My brother won't be back over to my place until this weekend, and I am hoping to have the pinion out before then. I don't have a torch either. Just brute force and ignorance!

Now that I think about it, I might be able to take my press partially apart and reassemble it around the differential as the press lays on its side. Hmmmm. I need to get some free time to head out to the garage.

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Casually looking for a Clifford hyperpak intake for cheap.

I would suggest, smack the pinion, tap the case. Also be careful while under the car.

Press uses a bottle jack doesn't it? I would remove that and make sure it can exert pressure sideways before doing anything with it. Depending on the valving / reservoir design it may not work.

Hammer hits won't be that effective in the car if its seized - most of the shock will be absorbed through the bushings.

How about an air hammer? The vibration may knock it loose. I'll second the heat option - not only watch the gas as mentioned but also hose out any residual oil from the housing. Oil fires are just as fun as gas.

Good suggestions all, thanks. I will have to weigh all my options. My press does use a bottle jack and I am fairly certain it doesn't work sideways. Sounds like if I can't get the range of motion I need under the car to swing a sledge, I will pull the housing and use the press.

Time to get all John Henry on it!

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Casually looking for a Clifford hyperpak intake for cheap.