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I've read how people use come-alongs to line this bolt hole back up, but I don't have one (I have ratchet straps) and I can't see where to hook up to pull the diff towards the driver's side. Everything I've found is to pull it to the passenger side.
I can't seem to get enough leverage with a big pry bar, is there some best spot to use or something? I just cannot get the diff to move more than a quarter inch.
Is the tire on the ground, on a ramp, or off the ground? If on a ramp or the ground, try jacking the frame up a little higher an see if it lines up. I did my bushings with the front tires on a ramp, and needed to use a come-a-long to pull the axle in.
I've tried both with the tire on the ground and off.
I'm not sure if it's semantics or not, but when you say "use a come-a-long to pull the axle in" I don't need the axle to move in, I need it to move out, towards the wheel.
That's strange... What changed from when you took it off from putting it back on? You've got a solid 2mm misalignment from the hole. That's significant!
Put a floor jack under the diff on that axle. Then put a floor jack under the frame as far forward as possible on the opposite side, with the wheels facing to the side. Jack up until that tire is off the ground, then adjust the jack under the axle needing the bolt until it is the right height.
Try prying between the end of the axle and the connector the bolt goes through. If needed, have someone pull on the jack handle on the opposite side at the same time. All you need is to shift the axle out a small amount. It you can get most of the weight off the tires and keep the end at the right height, it won't take much much to move the axle over.
I just use a spud wrench, or a taper bar, get it in one side, pull it into place, and slip the bolt in from the other side while you've got it lined up
Ok, here's how I did it, in case anyone else is having trouble.
This is getting the bolt back in for the DRIVER'S SIDE axle.
I took the passenger side off the jack stands.
Place the jack under the passenger side leaf spring u-bolt plate (I believe this is what it's called).
With the passenger wheel off the ground, push/pull the jack towards the outside of the truck, in the direction of the passenger side. This will spread the wheels apart, pulling the axles with them.
Lower the jack so the passenger side wheel is now on the ground firmly, pulled out.
This pulled the bolt hole over 90% of the way, and I got the last 2mm scooted over by pushing HARD on the driver's side tire, and shoving the bolt into the hole when it lined up for the split second.
Then tighten and torque to spec.
