Passenger CV Axle (Issues)

audiboy86 · **Posted:** Thu Apr 14, 2011 11:51 pm

I pulled my passenger side axle tonight after it had started clicking. But now i can not get the main input shaft loose from the old CV. I figured it was just a snap ring and one good yank with the old CV in a vise and it would let go. But now i am a pickle fork one ball pen hammer and some sanity short. :furious:

Now i am going to go have a few :5SHOTS:

and try and figure this out. Any ideas, help, or just plain suggestions would be greatly appreciated.

JL Rockies · **Posted:** Fri Apr 15, 2011 1:08 am

I dunno... I didn't have any problems...

LibertyCRD · **Posted:** Fri Apr 15, 2011 11:38 am

They are likely rusted together. I would recommend replacing the intermediate shaft at the same time, and grease the splines up good before putting it all back in.

A guy named Eric sells the I-shafts for around $65 or so and that's a LOT less than the dealership gets. I got his info. from Tommudd.

audiboy86 · **Posted:** Fri Apr 15, 2011 2:15 pm

I finally got the thing to let it loose after slaming it through a trailers pintle hitch. I found about 1/2 the splines twisted or missing. I just found it amasing how strong these housings are i hit it with everything i had. And it was taking chips out of every one of them and not moving even my 10lb sledge did nothing :shock:

. I was close to taking a torch to it. But now for the bad news Eric is no longer with the company called them today and it is now about 100 for a new shaft shipped.

CATCRD · **Posted:** Fri Apr 15, 2011 6:40 pm

The same thing happened to my buddy when we had to replace a right front CV on his gasser. The snap ring had rusted enough that it wouldn't just slide out anymore. It took a big bench vise and some MLB type hits with a 10lb sledge to get it to come off.

warp2diesel · **Posted:** Fri Apr 15, 2011 8:27 pm

If the outer joint is bad and the joint does not pop off, use an abrasive saw or cutter in a hand grinder to slit it, crack and remove. Much better than trashing a good shaft. With the 4140 shaft the last thing you want to do is heat it up and mess up the heat treating.
To properly harden 4140 it has to be heated up to a specific temp (think 1250F but not sure) for a specific period of time, removed from the furnace and air quenched. Then you heat it up to a lower temperature (recall 550F but not sure), shut off the furnace and let it cool until you can pick it up by hand. If you really want the exact temps, you can buy a chunk, and the Sales Engineer will let you know for your application.
You can see why using a torch may screw it up. Too soft, the splines will strip, too hard the shaft will crack.

audiboy86 · **Posted:** Sat Apr 16, 2011 1:28 pm

Oh i understand thermodynamics i just wanted them seperated so i could return the CV for the core. Had no intentions of using the shaft once i got it removed anyway since i was more then likely destroy the splines either way. Also since i took a few large chunks out of a 10 lb sledge and broke the handle on a 1 pound ballpene.

audiboy86 · **Posted:** Mon Apr 25, 2011 9:54 am

Modified a set of NAPA CVs
I have cut down CVs before on my liberty and a toyota pick-up and these by far were the most labor intensive. The first set i did were the orginal mopar set and at 100K i started to get the dreaded click on the drivers side. So I bought a NAPA CV with the intentions of cutting it down to make it workwell after getting the boot off i find this.

No where near the mopar design with ball bearings these have caps and what they call runner bearing nods. After cutting the housing and reinstalling i was still getting binding so i pulled it back apart and put it in the vise at the smae angle it sits in the car. It was binding on the bearing runners so almost 4 hours with a chop saw and a die grinder I offically have the first cut down NAPA CVs. Excuse the bad photos the cell phones camera didn't like all the shiny surface.

arengant · **Posted:** Tue Apr 26, 2011 4:02 am

Awesome, can you show a mock up with the intermediate shaft to show the angle it can handle now? Maybe more details on what/where you cut?

audiboy86 · **Posted:** Tue Apr 26, 2011 9:44 am

I already have it under the jeep and working but i can get a few photos with it installed and i am working on a full how to write up.

arengant · **Posted:** Tue May 03, 2011 11:02 pm

Sounds good! This and a limiting strap should let us CRD feel confident to go taller...

Passenger CV Axle (Issues)

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