Removing Broken Inner CV Axle Shaft

Vermejo · 10-25-2008, 02:39 PM

When the CV breaks at the inner axle shaft extraction or teardown are the two options. The broken shaft in inaccessible by simple measures.

-Jack and support front end safely

-Remove tire, damaged CV and shock assembly (Plenty of write-ups on CV removal)

-Mark and indent center of broken shaft

-Wedge paper into the bottom of the housing to catch metal shavings

-Make sure your drill fits into the tight space at a straight angle. If the drill does not fit removal of the LCA is required. The DeWalt I used was big and had to be operated upside-down to get a straight line on the shaft

-Use a 5/16 cobalt/tungsten carbide tip bit for drilling. Drill a pilot indention with 4WD disengaged to spin the shaft and center the hole more easily

-Engage 4WD and front locker and drill approximately ½ inch deep

-Start the 3/8 tap by hand and continue with a wrench. Back the tap out every so often to clean the threads and clear metal particles, wasted gear oil will assist the tap

-Thread the 3/8 bolt and remove the shaft with a slide hammer. The Harbor Freight model I used was 3/8 and threaded directly into the shaft. Otherwise use a 3/8 bolt and slide hammer jaws. (in the tools pic note the shaft piece at the end of the slide hammer)

-Thoroughly clean the housing to remove any shavings/debris

-Change the diff fluid and check the drain plug for metal after a few miles if need be

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