07 AAM 11.5 pinion gear removal - HELP - Dodge Cummins Diesel Forum
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post #1 of 4 (permalink) Old 07-25-2010, 10:54 PM Thread Starter
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07 AAM 11.5 pinion gear removal - HELP

installing new carrier bearings one was pitted pretty bad, took apart and cleaned the axial-gear posi unit, replaced inter-outter wheel bearings,seals etc... just a basic inframe diff-overhaul.... however, the pinion-gear bearings need to be replaced as well. i've done alot of work on the older stuff but this is the newest diff i've torn into. i was pretty impressed with simple adjustable load sets for the carrier bearings, no more spreding the case and shimming for bearing load, very nice... however, one nice thing typically leads to something like the pressed in pinion-gear....lol

so anyone know of a puller out there that will push this unit out ? i certainly cannot find one...

i would really appreciate hearing from someone, anyone that has done this without removing the the entire diff and using a press... there HAS to be tooling for this ??? if there is not i'll guess i'll just have to make one!

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post #2 of 4 (permalink) Old 07-26-2010, 02:15 AM Thread Starter
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pinion gear shaft stuck in seal side bearing

after some research found that the bearing closest to the ring gear is pressed but the seal side bearing is not. this pinion will not come out of the seal side bearing... likely the seal side or input side bearing is somewhat seized to the shaft from heat generated from friction from the bad bearings..


i have rebuilt at least twenty diffs in my time and have never seen one as stuck as this one... don't mind putting heat on the bad bearing but did not want to heat the pinion shaft...

any other ideas ?
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post #3 of 4 (permalink) Old 07-28-2010, 12:19 AM
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If I remember correctly, the factory driver tool threads on to the pinion's threads then the pinion is driven out by hitting the factory driver tool with a mallet.

I think that you could use an old pinion nut, and hit that with a mallet or heavy hammer so you won't ruin the pinion threads. You want to be ready to catch the pinion gear so it does not fly out the other end(of the housing) though.

2004 Dodge 2500 4WD, 5.9L CTD, 6 speed manual, 4.56 axle ratio, 9.25" Truetrac front differential, 11.5" TracRite rear differential, 4" Rancho lift, JKS swaybar disconnects, 37" BFG KM2, H2 wheels, Magnaflow exhaust, Smarty JR
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post #4 of 4 (permalink) Old 02-02-2015, 04:36 PM
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I'm having the same issue... I had an old pinion nut I put on and have used a 2lb ball peen. It moved about 2" or so and stopped. I've been out of town but I plan to use more force when I get home... Not sure if there's some sort of trick to this or not.
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