My 96 suzuki side kick front passenger axle won't go in due to pin int differential in the way.How do I resolve this?

Lift and support front end on suitable jack stands preferably on frame. Remove right front cv axle, stub shaft, and seal. You will need to pull the right front brake caliper assembly loose and place to the side. Then remove bolts from shock and upper control arm and hub nut to do this. Next, remove axle lock actuator on passenger side of front axle. Place a drain pan underneath front diff cover and remove cover and drain axle. In the center of differential there will be an 8 mm head bolt holding spider gear cross-shaft. Remove bolt and cross-shaft only! Push inner axle in until clip clears inside of passenger spider gear. Set clip aside and push/pull axle shaft straight out to passenger side.

CHANGE AXLE OUT .ABOUT 70.00 DOLLAR PART. REPLACE SEAL AT THE SAME TIME

its located on the backside of the front differential on the passenger side of the differential, it comes directly out of the differential. pretty basic an easy fix. disconnect the wiring harness losen the actuator take it out, check fluid level of the differential an put new one in, tighten it up an put the harness back on

when removing the front axle i believe that you must open the front differential cover and inside the dana you will see a small 8mm bolt located on the spider gear center it holds the pin bar in place and the pin bar holds both the upper and lower gears in place with a small washer below them. be careful when you pull the pin bar out to make sure the gears stay in place (upper and lower) do not let the washer fall out of the spider cage assembly. Then, carefully slide the U pin that holds the axle in (there are two of them one for the left axle and one for the right). Once the U pin slides off the axle the axle should slide all the way out of the whole differential - Note if the U pin you see at the end of the axle does not come off easy just push the axle IN ward towards the center of the differential and then slide it out with a small screw driver ..

Pull the cover off the rear differential. Remove the 5/16 headed bolt that holds the differential pin in. Remove the pin. Push the axle in and remove the C clip. Then pull out the axle. Replace the pin so the spider gears don't fall out if you turn the diff with the axle out.

It sounds like your limited slip differential is in need of a fluid change.
The clutch packs in the axle require a special friction modifier,about 4 ounces added to the axle lube,which fixes the chattering issue.
I'd suggest someone drop the axle diff cover and check or change the
fluid,to see if there are any big metal pcs. in there. If there is no damage,drain the diff fluid and add the friction modifier,only if a SLD..

Note: Only add the friction modifier,if you have a limited slip differential.
Since I can't physically see your vehicle,make sure a mechanic does
it right.

Have the wheel hub bearings checked.

The attached hub and bearing when installed keeps everything together. After removing all items from the axle outer end the inner shaft is locked in by a c ring. It simply snaps in and the same upon removing the shaft. The c ring will stay on the shaft when taking the axle shaft out

In order to replace the seals, remove the front diff assembly. To remove the passenger side seal, I would suggest removing the tube assembly (5 bolts). This is due to a steel washer that goes on the end of the axle. If you just pop the axle out, it is tough to get the washer aligned and back on the shaft. Use anerobic sealer to seal the housing to the diff case. The drivers side you can pop out with a hammer.

There is a actuator on the front axle. These are notorios for going bad. The new one will usualy come with a slug (round piece of metal) to install in front of the new actuator so it will engage your 4X4 faster. The factory setup was slow due to the pin having to move so far. The actuator will be towards the front of the vehicle on the passenger side of the differential.
Have a great evening