Removing Broken Inner CV Axle Shaft
Oct 25, 2008 | 01:39 PM
#1
Thread Starter
Registered User
Joined: Feb 2007
Posts: 481
Likes: 0
From: Las Cruces, NM
Removing Broken Inner CV Axle Shaft
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
-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
Thread
Thread Starter
Forum
Replies
Last Post
FS[GreatLakes]: Toyota collection part out
88sasturbotoy
Axles - Suspensions - Tires - Wheels
3
Jan 30, 2026 01:57 PM
FS[PacNorWest]: Rear chromoly axle shafts
A2theK
Axles - Suspensions - Tires - Wheels
5
Jan 10, 2016 10:18 AM
FS[NorAtl]: some RC stuff crawler and racer
akaphilly
Misc Stuff (Non Auto Related)
0
Jul 9, 2015 02:34 PM
