G-749 Re-build Project Phases
The guru that helped me with the 'catastrophic' portions of the re-build showed us a nice tip on removing the front axles.
AXLES
The front axles have 2 additional threaded holes in the cap. Once your bolts are out of the axle cap, insert 2 correct size bolts into the 'extra' holes. Alternate tightening them which forces the axle and 'cup washers' away from the hub and gives you room to tap the axle back in, allowing the cup washers to basically fall off.
MANAGING LEAKS
The NOS front axle inner seals are notorious for allowing gear oil into the hub. Some of this could be caused by sitting so once you're running, run often to keep things lubed. Additional causes can be internal pressure once the diffs get hot.
a) ensure all lines coming off diffs are clear and diffs can breathe. I used the combo turkey baster and hi-tech lips and blow method after using line wrenches to remove and not wreck any lines.
b) consider 2 inner axle seals up front. (see pics) right or wrong the new seals I found are narrower and made with new rubber.....so I doubled them up in the space normally meant for one. I'll let you know in 50 years if they held up but so far, no leaky.
I wanted to paint all exposed metal (wheel cylinders) but my mechanic friend thought I was nuts trying to detail the inside of a brake assembly. He's right but I still managed to get primer on most things. I scrubbed one set of brake parts for 6 hours before I could get adjusters to move and prep for primer.
Be patient and enjoy the tear-down. You're gonna be running soon, real soon.
The TM 9-8024 is handy to have on hand.