I'm trying to pull the axle shafts out of my new 8.25" rear end so I can change the backing plates. To remove an axle shaft, you have to remove the C washer from the inner end, but you can't get to the C washer until you push the axle shaft inboard. To do that, you must remove the pinion shaft ("pin") that separates the inner ends of the left and right axle shafts. The pin is held in place by a lock screw. I've removed the lock screw but the pin won't come out. With a light hammer tap it moves about 1/16" in either direction, but then it feels like it's really up against something-there's no give at all. It's not rusty at all, by the way. The shop manual just says "remove lock screw and pinion shaft" with no other guidance. I saw a video where I guy does this on a Jeep and the pin just slides right out. What am I doing wrong? By the way, my differential is a sure-grip, but I don't think that matters; the manual says the removal procedure is the same for the sure-grip.

The pin should slide right out, but there are a number of reasons why it might not. Scoring of the shaft being my first guess. Assuming that all of the lock screw came out, and you gave no indication that it did not, about the only thing you can do is hit it harder.

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Joshua

You might try moving the axles out a little so there is no pressure on the pin....but as Josh says they usually just push right out.

Use a bigger hammer and a piece of wood for a drift.

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Yeah....Im the one who destroyed this rare, vintage automobile.....

It came out pretty easily after I rotated the differential so that the pin was more horizontal.* It turns out there are some gouges in the pin where it meets the corners of the spring-loaded plates that push against the side gears. I guess those gouges were catching in the plate corners, and when I rotated the differential it released the pressure.

*Edit for clarity: I had the rear end up on jack stands with the U-joint flange down toward the floor. So initially when the pin was vertical, it was aligned in the direction of the driveshaft. I had to move it away from that direction to get it free. Perhaps it was hitting the pinion gear?