Halfshaft issue

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Screw-Rice

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Decided to say screw it and keep the car. Went and looked at a another car (GTO), but it just didn't have the appeal, I thought it would.

Started my hub swap last night. After much fighting I went and bought a 3 jaw puller this morning. Passenger side knuckle came off in a matter of minutes finally. Both rear shafts suffer from being in :q:q:q:qty weather.

Dismantled the driver side knuckle and then snapped the puller trying to compress the cv shaft. Proceeded to break another puller shortly there after. This is after a few cycles of putting heat and liquid wrench to everything. So elected to just remove the shaft and knuckle as one piece and let the shop doing my rear bearings/hubs deal with the issue.

Well trying to pry the shaft out of the diff, yielded no results. The passenger side shaft is hanging out partially free. I know the driver side should pop out in the same manner, without much resistance. However it is refusing to cooperate.

Anyone have any tips to help free it up, so I can run them down to get them swapped out? I slightly bent the ring gear on the shaft during my prying. Ordered a new one as insurance, just incase the one in there gets beat up during removal.
 
topher5150 said:
isn't there a snap ring keeping it in place on the knuckle
Click to expand...

Not that I'm aware of. Don't recall seeing one in the past when pulling one. Although I am wanting to just pull the knuckle with the CV as a unit at this point. The knuckle is basically seized to the shaft.
 
Huh... they always slide right out with a few wacks from a massive hammer, and a pry brar has always popped the half shafts right out for me.
 
There are c clips on the knurls of the axel. But the axels pop out with a screwdriver with little to no effort, something is up for sure but what? I don't know.
 
Correct, the halfs do just POP right out. The 36mm bolt end is a bit tough, if you have an air hammer they pop right off too, if not, just put the nut on just barely flush with the stud soak it all in PB brake free over night and take a piece of junk metal flatstock, and WHAM!! Hit that bitchhhh hard! lol
 
The 36mm nuts weren't too bad to get off. They were slightly seized, but a 2ft breaker bar + a 4' cheater bar made it easy. :lol:

Now that I have taken a break...and had a few drinks, I might make another attempt tonight before I crash out. Have to work tomorrow, so luckily this isn't my only vehicle.

I nailed the end mounted in the knuckle quite a few times with a decent (2.5lb or so) hammer. Also beat on the gear section with a rubber mallet. :lol:

Oh and my prybar is like 3'. Not overkill, but if I could get my hands on bigger, I would have. :p

Was funny seeing the look on the face of the manager at Autozone, when I brought back their "heavy duty" 3 claw puller in 6 pieces. Told them the 5ton rating was a bit exaggerated. :lol:
 
The CV is officially DEAD! Took the torch to the end mounted in the diff, then the 3lb sledge. The gear broke into multiple pieces despite not making contact. Think the heat finished off what the prybar started earlier. This thing is seized in there, and I have no idea as to why.

It hit me while I was under there. The guy that did my gears, used the one wheel method to pull the diff. He pulled the driver side, same side that is fighting me. I know, because I gave him the write up, and he had never done an IRS car before, but tons of solid axles ones.

Is there anyway he could have possibly put in a c-clip or something? I am going to email him, and see what he remembers. Did the gear install about 16 months ago, and I have had no issues. I REALLY REALLY REALLY, don't want to open up the diff.
 
Here's a pictorial. Hope this helps.

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Thanks GMAN, but I have done a few before, and have never had an issue remotely close to this. There is no reason why it should be locked in the diff like it is.

Almost ready to pull a Ripped Camel and get all retard strong. :lol:
 
If you put in a regualr non-irs carrier before without the correct side gears, than it will cause what you are facing. Sounds like you may be into opening the diff cover to get at the clip...
 
Icarus said:
If you put in a regualr non-irs carrier before without the correct side gears, than it will cause what you are facing. Sounds like you may be into opening the diff cover to get at the clip...
Click to expand...

There shouldn't be a non-irs carrier in there, but doesn't seem to be any other explanation. Going to crack open the diff tonight. I won't need to add a c-clip again will I? Think I remember reading once before, even a non-irs carrier wont require the use of a clip in an IRS car.

Also ordered a new CV (OEM Ford), but could take over a week to arrive. So having a parts store ship one in, and will have it tomorrow. Looks like I will have a spare CV to add to my collection.

Have I mentioned how much I hate dealing with gear oil? Only thing I truly despise screwing with.
 
Listen to Icarus, he has the right answer. That circlip as opposed to being slightly compressed by the tapered side gear is fully expanded up against the flat seat that non IRS side gear has, so it probably will not come out, you will most likely have to take the diff apart... Non IRS carrier users normally leave those clips out completely.
 
DieselDan said:
Listen to Icarus, he has the right answer. That circlip as opposed to being slightly compressed by the tapered side gear is fully expanded up against the flat seat that non IRS side gear has, so it probably will not come out, you will most likely have to take the diff apart... Non IRS carrier users normally leave those clips out completely.
Click to expand...

Unfortunately he probably is right, going to go pull it apart here in a few.

Not particularly happy it was installed in there, in the first place. Oh well, not much I can do about it now. Atleast I want have to service the diff again for awhile. :lol:
 
Alright, don't know if this really counts as an update.

Got the diff cover off. Upon inspection didn't notice any kind of clip on the shaft. However, it almost looks like a small portion of the shaft, has adhered to the large pin in the center of the gears. Thought it was fluid at first, but several attempts to pry it with a screwdriver made no change at all.

Don't really know diffs well enough to explain any better, and my attempts to take a pic were in vein. All I could get was a fuzzy pic of the gears.

Emailed the guy who did the install, and waiting to hear back. Asked if he could swing by and just take a look, and see what it is that I'm missing.


Edit: He will be swinging by Friday to check it out, and see what is going on with the CV.
 
The circlip is fairly thin, not a big flat one like the non-irs c-clips. It may be hard to see if it's right flat against it. You may have to take the center pin out and rotate out the side gears (like when rebuilding the t-lock,) an the try to get a pry bay in there at all on the end of the half-shaft and push it out from in the carrier, or have someone push the half shaft inwards hard and pop the clip off if you can. I'm not sure if you can get at it with the side gears in though...

EDIT: I was to lazy to rewrite this so perhaps try the bolded part first before taking it apart more...
 
Had my neighbor shove on the halfshaft and there is zero play. It's essentially fused to the damn center pin. They guy who did my gears will be over tomorrow, so I will update afterwards with what we find.

So much for my easy hub swap/brake upgrade. So far I am a few hundred bucks shy of what I spent for the damn car! :lol:
 
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