I'm looking at another school bus instead of fixing the one I got. I talked to the mechanic and he said that the motor and tranny are good but the last time they serviced the rear end there were some sizable flakes. Anyone ever rebuilt the rear end themselves or knows how difficult it is?
1989 TC 2000; 235,000miles; 5.9 cummins with Alisson 545; Straight veggie burning with onboard filtration. Converting to a Toy Hauler for the summers racing motorcycles.
I would prefer to just swap out rear ends than to go and try to rebuild one of those suckers... Basically you have to take the whole freaking axle apart... Then you have to deal with the heavy gooey messy parts, and the pinion gears, I think, need to be pressed off and on.... Naaaa... Swapping out the axle would be the way to go if I were you, thank God I'm not
It is rare that the entire axle housing assembly needs to be replaced. Most likely, what you would do is replace or rebuild the "pumpkin" -- the hogs-head shaped unit that the drive shaft attaches to the nose of. Strictly mechanically speaking, it isn't all that difficult to take the pumpkin out and in, but the darn thing weighs a... hmmm... well, maybe not a ton but darned close! And there is no flat bottom on it to place a common floor jack -- it would tip over and take some body-part off you for sure. A commercial gear and driveline shop would have the tools and know-how for handling the beast.