Stuck CV axle, tried everything for 10+ hours over the last week and nothing is working

I originally was replacing a $15 seal between my passenger side cv axle and the front diff because it was leaking. What looked like an easy task has become an absolute nightmare. I’ve used slide hammers, crowbars, cv axle pullers, pry bars, air hammers, and even a 20lb sledge hammer against the cv axle puller, nothing is working. Am I missing something? The wheel is fully removed from the LCA, the whole axle moves freely and it is halfway out, about a centimeter gap between the diff and axle. I’ve put hundreds of pounds of force against this thing for days and I’m ready to give up. Any highly unique/maybe there is a clip I’m missing comments would be greatly appreciated haha. Thanks!

 

Can you post pictures of the the repair?

 

One question, you noted to have the wheel off, but do you have the axle nut off, axle loose, and the lower ball joint unbolted and moved forward?


If it isn't coming out and you have things properly disassembled, put the CV back in and rotate it a quarter turn. If the open part of the C clip is at the bottom, then it comes out and goes back in much easier.

 

Have you successfully removed these before?

 

The axle nut is still on because I’m just taking the one side out for a seal, that’s what I saw people do on YouTube. The ball joint and LCA is disconnected and the axle can move freely with the wheel.

 

No this is the first time I’ve done a CV axle

 

Take the axle nut off. 35mm socket and don't forget to retorque. That thing needs to slide way out to get removed. I haven't watched YouTube videos on it but did remove the driver's side to swap in the ECGS bushing and it was a bear with the HF pry bars but eventually came out. Tried the air chisel but the third largest pry bar against the notch/flat and a BFH encouraging it got it moving.

 

There's a C clip on the inner end of the axle stub that must be compressed somewhat evenly or it will hang up, I don't see any tool marks and the CV removal flats where have you been prying/beating?

Place a pry bar on those flats and give a solid tap away from the diff rotate the CV to the next flat is down firm tap rotate firm tap etc etc and it should work itself out.

 

Also how can I tell the direction of the c clip?

 

There is a clip internally. You have to line it up to remove it. Spin it a bit and then hit it out/slide hammer. If it doesn't budge, spin a bit more and do it again. Repeat till it comes out.

 

That was the picture before I started, half the paint is off this thing now. I’ve tried all of that.

 

Red are the removal flats, blue is where the tip of the prybar should go green is the force direction, and again tap firmly but don't wail on it then rotate 1/3 and repeat.

 

This. We were typing at the same time, ha.

 

You just have to keep trying it by rotating and tapping each notch. When it comes out you'll see the design and make sure you reassemble with it down.

 

I’ve tried all of this but maybe I slightly missed the right spot when rotating, tomorrow I’ll try more rotating and beating

 

I DO NOT recommend this method as it can tear the boots and damage the CV's but if they're being replaced...

I have resulted to using the knuckle as it's own "slide hammer" to remove particularly stuck CV's reinstall the knuckle to the outer end get the CV angles as straight and flat as you can and pull straight towards you in a quick jerking motion and sometimes that's enough to compress the clip evenly.

Again I DO NOT recommend this but if you're at the end of your rope and they're already junk what the hey eh?

 

A second set of hands definitely helps to hold the outer stub straight and pull a bit as you hit it out.

 

@tluke81 where are you located? Somebody on here might be able to help you out.

 

Nah. Get that out of the way. It is a lot of extra mass that you are fighting.