Is there a trick to un-staking the pinon nut? I thought it would be easier to change the pinon seals with the engine out, but I'm having a hard time removing the nut. I'm thinking it might be easier to grind the nut with a dremel tool and use a new one after I change the seal.

 

I sometimes have luck using a center punch and hammer to uncrimp.

Your idea will work, but don't grind anything except the staked portion of the nut. Grinder vs. pinion shaft = not good. Replace the nut with a new one.

 

Here is how I do mine:



http://www.4crawler.com/4x4/CheapTri...eal/index.html

 

Thanks for the info. I'll try a different punch with more taper to the point and see if that will work. I didn't have any problems on the transfer case nuts, but the diffs are way tougher.