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I have never seen a rotor that needs the axle nut removed do you have a picture and have you removed the caliper and caliper bracket it may be rusted enough to cause it to look that way
If you bought new drive axles, they may not have given you the right ones (too short) - they did this to me with my 93 Subi - (I own a 93 Toyota Corolla DX).
Make sure that you are pushing the drive axle in as far as it will go into the tranny - and when putting the other end in the hub assembly - make sure it is lining up (there should be grooves on the axle that MUST lign up with the grooves on the inner portion of the hub assembly.
After pushing the drive axle into the driveline you should not be able to pull it out by hand at all (without effort).
Please let me know if you need further assistance.
1. Jack up and support car on jack stand. Make sure to chock wheels and or lock the parking brake on. 2. Remove wheel 3. Remove cotter key, castle lock and nut at center of rotor that attaches the axle. - If you lack and impact gun to remove this - it is easier to loosen this nut with all of the wheels on the ground. 4. Remove outer tie rod from spindle, Tap out with hammer. Should not require much force. 5. Remove the single bolt from the lower ball joint and separate from spindle. 6. Pull axle out of spindle and remove from transmission. This may require you to drive this out with a hammer and punch ( I use a brass punch), make sure not to damage threads if you intend to reuse the axle.
To install reverse the procedure. Make sure to replace any cotter key removed with new ones during install.
Torque specs you need are
Ball Joint to Spindle = 91 ftlbs Tie rod to spindle = 36 ftlbs Drive axle hub nut = 166 ftlbs
Remove wheel, brake cliper, cliper mounting bracket, brake pads and rotor.
Remove tie rod end and strut from spindle,
Remove large drive axle nut from center of hub by removing cotter pin and nut cover
Remove the ball joints 2 nuts and 1 bolt
Pull assy. lose from drive axle.
Take complete Hub assy with new bearing to an automotive machine shop and have them disassemble hub and replace bearing.
Reverse steps to reinstall
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