Removing a Powertrax - Need Quick Help!

quivvy · **Posted:** Thu Feb 15, 2007 1:45 pm

I got into an accident in my KJ and bent the rear right axle shaft. During repairs, the mechanic cant get the C-Clip out to release the axle. I put it in a while ago and dont remember anything about doing it, and didnt keep the instructions. Seeing as how the jeep is apart in the shop, I can be of no real assistance. Anybody know of any special tools or instructions needed to get the powertrax out? Thanks!

-Adam

ATXKJ · **Posted:** Thu Feb 15, 2007 2:32 pm

I haven't done a Powertrax - but C-clip axles in general and the 8.25 in particular need to be pushed in ~1/2" to allow you to pull the clip - if your axle shaft/housing is bent enough that it won't move - I don't know that you have non-destructive options.
For instructions - Camper posted this down in the Tech section - hope it helps.
http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?t=489

Jeepjeepster · **Posted:** Thu Feb 15, 2007 2:46 pm

Yes, the calipers must be taken off and then the axles can be pushed in to expose the C-Clip. The Passenger side c-clip is alittle tight when putting it back in with the locker in. It would of been best to file down the c-clip some before putting it back in, I forgot to do this and just pushed it in.

Ive read that its best to turn/push/pull the axle while someone tries to get the c-clip out. Sorry I cannot offer more advice.

quivvy · **Posted:** Thu Feb 15, 2007 6:51 pm

well, i called up powertrax tech support and relayed all the information to the tech working on the jeep - as well as the powertrax instalation instructions. the jeep tech also tried many of his own tricks and it wont budge. powertrax tech support said there is a likely chance that the axle is bent too much to allow the c-clip to drop out, or the powertrax internals are bent. long story short - it needs to be cut out

this little adventure keeps adding up$$... :twisted:

Edwin · **Posted:** Thu Feb 15, 2007 7:47 pm

Let us know how it turns out.

dcljeep · **Joined:** Wed Jul 13, 2005 9:08 pm **Posts:** 9

Regarding the removal of the C-clip. use a very strong magnet. it takes a little manipulating but it will work no problem.

Troysterr · **Posted:** Sun Feb 18, 2007 9:07 pm

When I installed my Powertrax the C-clip didn't just fall in--I had to push it in with a screwdriver. So I tried to take it out a few months later (to put the spider gears back in, just for the winter) and nothing I tried worked. I even made a little hook from a paper clip. I was able to get the hook under the C-clip and pulled as hard as I could, but it wouldn't come out.

I'd like to get a pair of stronger axles, but I'm afraid to buy them because I may not be able to get that C-clip out.

I didn't try a magnet, though. It's worth a shot.

tjkj2002 · **Posted:** Sun Feb 18, 2007 9:23 pm

Well if you really need to get those c-clips out try taking a pair of needle nose pliers and heating up the last 1/2"-1" of the jaws with a torch and bending them to make 2 claws.If It won't reach all the way in grind the edges down so you can slip them in and then grab the open ends of the c-clip and pull out.It's hard to explain how to make them but it's hard not to figure it out,just a thought though.

Jeepjeepster · **Posted:** Sun Feb 18, 2007 9:36 pm

Troysterr wrote:

When I installed my Powertrax the C-clip didn't just fall in--I had to push it in with a screwdriver. So I tried to take it out a few months later (to put the spider gears back in, just for the winter) and nothing I tried worked. I even made a little hook from a paper clip. I was able to get the hook under the C-clip and pulled as hard as I could, but it wouldn't come out.

I'd like to get a pair of stronger axles, but I'm afraid to buy them because I may not be able to get that C-clip out.

I didn't try a magnet, though. It's worth a shot.

Thats no good at all.. I did the same thing, pushed it in with a screw driver. I dont know why it didnt pop into my head to file it down some. I guess I will have a fun time if I ever want to take it out.. The way its been acting lately, it may be soon.

It was snowing last night, and of course I was out driving around in it. I was doing donuts and stuff that I shouldnt of been doing. I found some hills to see how my tires did in snow and all that. The locker wouldnt kick in. I could hear the teeth grinding and carrying on since it wasnt engaged. I of course didnt sit there and let it grind. I could pull the ebrake up some and it would engage... But sometimes I had to pop it into N then back to D for it to engage. Its been in almost a year now and even did fine offroad with the Midwest guys yesterday.. Idk whats up.. Thats the first time Ive ever had it in snow.. Maybe they all do that in low traction situations?

unixxx · **Posted:** Mon Feb 19, 2007 1:44 am

I figured I'd write a little summary of the problem in case anybody else runs into it:

Jeep Liberty Wikibook wrote:

The Chrysler 8.25" uses c-clips to hold the axle shafts into the differential side gears. Limited clearance between the axle shaft c-clip grooves and side gears can make c-clip installation and removal difficult. When c-clip installation is difficult, selecting thinner c-clips should allow easier future removal. ARB Air Lockers actually come with multiple c-clip thicknesses from which the installer can choose.

I actually just installed my ARB and used the thickest c-clips that came with it. While they were a little tight, I still managed to get them in with my hands. Maybe I should have selected one size down....

Edwin · **Posted:** Mon Feb 19, 2007 6:19 pm

My c-clip was easy to get in, but I ain't tried to take it out yet.

jereosbou · **Joined:** Sun Sep 10, 2006 10:22 am **Posts:** 97

i had the problem with mine and finally just cut it out by lining up on the center of the c clip and drilling it with increasingly larger bits till it was split in half. then just bought a new one when the though finally dawned on me it took about 15 minutes

krazz1e · **Posted:** Wed Feb 21, 2007 7:13 pm

wiggle the axle shaft back and forth and it will fall right out.

jereosbou · **Joined:** Sun Sep 10, 2006 10:22 am **Posts:** 97

i spent 18 hours wiggliing pulling magneting lube ing spinning at high speed pushingin and out etc.etc. then finally left it for the week and came to the idea of cutting the c clip new ones are 2 dollars at the dealer and its simple as pie to cut it with a drilll bit.
the next one you put in clearance it with sandpaper or a grinder till it slips in without any force then it will fall back out.

Removing a Powertrax - Need Quick Help!

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