This is stemming from this thread:
http://dieselplace.com/forum/showthread.php?t=39284

Can someone tell me a good way (If there is one) to get the flange off of the stub shaft on the Pass. side to get to the seal?
Thanks,
Jason

Anyone? The leak is gettin kind of bad and mobil synthetic isnt too cheap!

Well, I'm not an automotive tech, but I have removed the front axle out of a k1500. I doubt it would be too much different than a K2500's. You can start by removing the cv joints from the axle and moving them out of the way. If you can take apart the section that is leaking from there, it would be best. There are 4 bolts on a 1500 holding the axle in place. Don't know how many hold the bigger one in. Once those bolts are out, it comes right out. The are heavy, so help would be advised.

Rienke, you think I have to remove the whole axle to get the flange off? The flange I'm talking about is what the CV joint bolts up to. There is a seal behind that flange but I cant figure out how to get the flange off! I tried a puller but was afraid I'd break the flange and then really be SOL!
Jason

My truck is in PA right now, so I can't go out and look to see if it is just like the 1500's. If you can get a pic and post it, it would help. From what I remember, if the CV joint will be out of the way once all the bolts are removed, then technically yes, you can take it apart with the pumpkin still in place. BUT, when we took ours apart while on its side, pieces fell out. We got it back together just because we had another unit laying beside it for reference. I don't know if you can get it back together while horizontal, but then, they may be different units too. I am willing to wager that it will be worth your time to remove the whole unit, the put it up verticle before splitting the seam. It's not that bad of a project, but a helper is handy. I have only seen those things leak at the pumpkin and not at the place I think you are mentioning. On second thought, is it leaking at the axle or axle housing? Anyway, if you can get a picture pointing to where your problem is, I (or more qualified techs) could be able to help you out more.

Reading more into this, is it leaking around where the axle comes out of the housing on the passenger side? If so, the whole front diff will have to come out and apart to release the axle from the housing. IIRC, there are clips holding the axle in place. You should see this when all apart. I have not replaced the seal that I think you are mentioning before, but I am guessing that it is similar to the ones on the rears, and can be removed either fairly easily, or need a slide hammer. You should be able to pick up a new seal at the dealership. If you do take it apart, the backlash in the gears should not require an adjustment if nothing is changed. It gets adjusted via a locking tab and once freed, you can turn it in or out depending on what's needed, but everything should be left alone and put it back together the same way it came apart.

To wrap this up, you would have to unbolt the cv joints, then the front drive shaft, the connector on the motor than engauges the front axle, then the bolts holding the braces in place. Like I have said before, the k1500 was heavy and the 2500 axle will not be any lighter, so make sure you have someone giving you a hand. Split the axle at the differential, and once apart, you should see the clip holding in the axle. Remove the clip and slide out the axle and inspect the seal, and replace. After the new one is installed, put some grease on the seal to keep from tearing it. The housing should go back together the same way it came apart. If you have the tools and capabilities, the housing can be removed in a couple hours. If you have the seal ahead of time, it can be a one day project.

You're exactly right. The front diff had to come out and then the clips come out from the inside. I took it to a shop today because I dont have the time to do it myself right now (It cant seem to rain here) and I need my truck for irrigating. The water pump is taking a dump also so thats why I just took it in.
Thanks for your time and help!
Jason

No problem, I hope they get it fixed for you.

You dont have to take the front diff assembly out. Sorry I didnt catch the post sooner, its not a bad job to do.

You dont have to take the front diff assembly out. Sorry I didnt catch the post sooner, its not a bad job to do.

Then how do you get the axle shafts out? :confused:

hit them with a hammer, they will come right out.

Right side you just pull the axle tube and all out. Left side you just knock it out with a hammer. As long as you have one the newer style axle that is not a complete circle, but has cut outs. The full circle type of the older trucks, it can be done, but it a really tight fit. The newer ones are nice to do.

Yeah, I know the mechanic I ended up taking it to had to take it out to get to the clips. Not that big of a deal though, from what I gathered. I just didnt have the time to do it.
Jason