and no you don't have to remove the axels completely you just have to pull them out enough to clear the third member. but if you don't remove them completely you run the rick of damaging the inner axel seals by allowing the axels weight to rest on the sealing edge. and once you have the knuckle off to sldie the axel out all the way is simple enough. just remember to support it's weight watch how you pull it out so you don't damage the inner axel seal.
if you don't remove the clips it is hard to do since your brake lines and all are still attached and makes it dificult to get it lined all up to get it out, just do like mentioned above and it will be easy for you. the cone washers on the arms might give you a little trouble but you can just tap on the arm and it will pop out. I've now done it both ways and the way mentioned above is so much easier to deal with. put the caps in the free position, pull the caps, pull the clips, remove the bolts from the felt seals on the back of the knuckles, loosen knuckle studs, remove arm, lift and rotate knuckle and slide it off, if brake lines are too short remove the calipers. take some wire or a bungee cord and tie it up so it isn't hanging on the brake lines. rotate the flats of the birfield joints up and slide them out. remove exchange third, this is a good time to replace inner axel seals too and for the cost it's worth it. but depending on when they were last replaced it's up to you. mine cost 6$ a pc.
it's also a good time to check the knuckle wiper seals too for damage. this would also be a good time to martack the axels and remove the inner clips inside the bells of the birfields if you done this already or don't know how to do this. go to pirate and do a search
www.pirate4x4.com/forum go to the bulliten board. but it's named the martack for a reason someone here can give you details. I just threw mine through the frame tube above the rear tires and broke the inner clips. and followed the instructions from there. was easy and now if or when I break a birf it will be easier to change.
gr8 post derek
