Rear axle refresh questions

Mustang5L5 said:

1.) Axle tube vent. What size threads are these so i can get a plug for it while i clean and paint it.

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You don't. just leave it open and clean everything.
Glass bead blasting is the quickest, easiest method to do the outside of the assembly.

Mustang5L5 said:

2.) I want to clean the sludge out of the housing. 21 years of diff fluid and 100K miles does not make a pretty sight. Can i remove the diff? I assume i unbolt the two journals and pull it straight out? When i put it back? nothing needs to be reset right? Drop it in and torque down the bolts? I don't want to have to reset anything to do with the gears at all.

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There are many sites with instructions how to tear-down the housing, and yes, it's quite simple.
In a hand basket;
remove the center pin
pull the large pin out of the differential
tap the c clips out
pull the axles out
remove the 4ea cap bolts
pull the ring gear assembly out

If you don't damage anything, people have successfully rebuilt their housing using the original shims and bearing BUT I suggest you use new crush washers.

Mustang5L5 said:

3.) If i remove the center diff, how can i clean out the inside? Powerwash at the car wash? Brake parts cleaner?

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409 or any grease cutting cleaner and a stiff parts cleaner brush will do most of the cleaning. Bring a healthy elbow because your gonna need it.
However, if you decide to do this, you're not going to use the original bearings on the Pinion.
If you remove the pinion, your going to have to buy new seals.
It is a PITA removing the bearings and seals from the housing!

Mustang5L5 said:

4.) Remove axle bearings. Slide puller??

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Yes, or a really long drift.
Again, if you remove these bearings, you'll need to buy new ones.

Mustang5L5 said:

5.) Remove upper control arm axle bushings? I assume i can drill out the rubber and bang out the sleeve with a hammer? How do i push the new OEM bushings in?

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That is one way.
If you have an air-hammer... I'd use that with a blunt chisel and drift them out.
This is a real PITA... consider yourself forwarned.


Good luck
Dana

The tube vent does come off, it's 1/4 npt I think.

This might be obvious but keep track of what side each cap and shim(s) were on and replace the same way. BTW if carrier preload is correct, you should have to tug it of there or use a big screwdriver or prybar. When you put it back, you might as well check backlash, if you have a dial gauge or can get a hold of one.