Heckova time getting XRT axle shaft out. Help!

RenoHuskerDu

We've tried everything to get the driver side axle shaft out. The instructions (see pic) say to pry it out with a screwdriver. Well, that doesn't work. We've put penetrating oil in there as best we can, and tried tapping in wide chisels to add some outward force.

No luck.

Has anybody BTDT? It's an aluminum case, so we can't heat it with a torch. That little "Compression Ring on Spline" needs to be overcome to get the axle shaft out, and I suspect that it's rusted in its groove.

Attached Images

HalfShaft.jpg (125.0 KB, 0 views)

BGW

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Fairtax4me

With that design it’s very possible the splines are rusted together. Bigger prybar, and work from both sides to try to wiggle it out.

RenoHuskerDu

Yep, that area looks like it has no lubrication unless the seal is leaking on the diff. We've been at it for a week now, took a few days break to do other tasks around the ranch. Gotta get back on it, using two wide chisels to apply force and impact. If i break the diff case, shudder ... hopefully my homemade penetrating oil has made it in there by now.
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Fairtax4me

Are you replacing the axle or just rebuilding it? The inner joints can usually be rebuilt without removing it from the diff if it’s really stuck.

If that’s a telescoping joint (the shaft moves in/out of the cup) then remove the band and the boot, wipe the grease away and there should be a cir-clip just inside the end of the cup. Pop that out and the joint just slides out. Be sure to have a rag or container under the joint so the bearing balls don’t fall on the ground and roll away.

bobbycason

I just changed out the axles on a RZR 570 and they're similar to this. The way I do it is grab the shaft and use it like a slide hammer as there's usually a little play in them. If they've been in there a while they may be rusted together so it may take a few good hits.

RenoHuskerDu

I was reluctant to put that much force on the inner CV. God only knows how long the shafts have been in the diff. We finally took the inner CV apart in place, and replaced the boots that way. Whoever didn't grease up that spline with anti-seize some years ago, I'd love to spend 5 minutes with you at the dojo.