pinion removal

Is it a banjo style axle? I just took one apart. I used a heavy press to push the pinion out of the housing and then a heavy three jaw puller to remove the roller bearing. I welded a 7/8 bar on a plate that road acres the press supports. It pushed up on the pinion. I pushed down on the housing with a piece of 4"pipe.
 
This is not a banjo rear end, its a floating axle in a 38 one tonner. The pumpkin was full of water when I opened it and now I am trying to disassemble as far as I can. The outer pinion bearing was not as bad as expected but still had some pitting and will replace. The two inside pinion bearings are now spinning freely and will leave them if I cannot find a safe way to get them out. Also, I assume the pinion bearings are lubed from the gear lube in the differential not packed with grease, please correct if wrong. Just looking for advice......
 

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A pinion puller for a banjo may work,plus a little heat, I made my own,
 

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KR Wilson probably made a tool for that application back in the day but I don't know what it would look like. If there is no way to jack screw from the inner back side of the case then a person would need some kind of a big C-clamp rig to force it out. If they had drilled & tapped the end of the splined part of the pinion, a slide hammer could be used. A person would need a clamp collar to use a slide hammer without a threaded bore and it would have to have some pretty strong clamping force on the shaft to work.

If someone had a *********** arbor press with a lot of bottom clearance, it might be possible to press it out using press plates or sockets. The only C type hydraulic press rig that I'm aware of is the OTC 5180 but that set is near 500 bucks and it probably doesn't have a deep enough throat at only 4 1/2 inches depth plus it would still have to recieve the shaft somehow as it presses out. A jack screw from the back side might be the best course of action and apply heat to the case to expand it as much as possible.
 
I did not have enough room for a bottle jack but you might. That would be my first try. A large C shaped piece of plate or a weldment could reach around the housing and a press would then easily remove it.
 
You have what is called a "clam shell" rear. The procedure for repair is shown clearly in the Canadian 39-48 shop manual. It is available from C&G (800-266-0470) as V-222. $60. It takes several pages to cover that axle. The book is a fine reference for anyone needing a "how to". Ford didn't publish such a manual, but the Canadians did.
 
I have a small bottle Jack that barely fits inside, just worried about pushing against the differential case.
 
Success!!! Bottle Jack inside and two propane torches heating the throat, came right out. Good thing too, inner bearing is trash/rusty paper weight.
 
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