Stuck CV axle shaft, need some help

I spent the day trying to replace both front CV axle shafts on my '06 4Runner. The passenger side was easy, I popped the old axle out with a 2' pry bar and put the new one in with seals and all. Simple job. However, I cannot get the driver's side axle out. I'm starting to think I'm missing something really simple, but in theory, it should just pop out with some effort.

Here's what I've tried:

• Pry bar method
• Slide hammer with CV axle puller adapter (here)
• A rope tied around the inner axle housing
• Hammering the axle housing with an 8lb sledge hammer
• A carefully positioned flat head screw driver slotted into one of the shallow notches on the inner axle housing followed by blows with a hammer (hard to do this solo, can't get really good purchase on the axle housing)

Here are a couple of videos documenting what I've tried (pry bar method not shown)

https://www.dropbox.com/s/8ax4odeh9gcfxnw/IMG_1322.mov?dl=0
https://www.dropbox.com/s/omtto8k2secg02u/IMG_1321.mov?dl=0
https://www.dropbox.com/s/8ucxvc4duqf78rw/IMG_1320.mov?dl=0

I'm sort of lost at this point. I'm starting to question if the cir-clip on the inner splined axle that slides into the diff-housing is mangled and it's not allowing the axle to slide out.

I really want to get this done. Open to ideas, need a little help here.

 

Have you tried rotating it, so you're not just prying on the same side? Does it budge at all?

 

Yep, I’ve been rotating and hammering. Rotating and prying. I’ve hammered and pried from both sides. Spent about 4 hours on this side before calling it quits.

I’ve tried tapping it inward toward the diff, just to see if that would help. It hasn’t.

There’s about an 1/8” of in/out play, but no more.

 

The service manual says to hook the end of the slide hammer on to the flat, but I've never had much luck doing that on stubborn axles.

I usually take a hefty cold chisel and a short sledge...I put the chisel on one of the flat parts and hit it hard. I go right under the front end to find the best angle of attack. It can take trying a few different positions to get the most solid blow when the truck is on jack stands as opposed to a lift (where you can walk under it).

 

I’ll give this a try and see if I can get a chisel to bite. The small hammer might be what I need so I can actually get a good swing—wielding the long handled 8 pounder is a chore from underneath. Hard to find a good angle of attack.

Thanks

 

Some shafts are just sealed in there and won’t come out easy. Seems like you’re doing everything right, just needs more hard love.

 

Sounds like a pain in the ass! I hope you get it!

 

The trick I use is to use two pry bars at a time; prying on both sides. It will usually come out without much fuss then.

If only prying from one side, you end up side loading the little clip inside; and hence the shaft doesn’t want to come out.

 

Going to go at it

I went at it with a 2’ pry bar and a 12” chisel on the opposing side. A couple swift pops with the chisel while applying pressure with the pry bar managed to break it free. Doing this on your back is quite a bitch, but got it done. The driver’s side oil seal (in the diff housing) was a pain into the ass to get out as well.

All in all this is a straightforward job made difficult by some unwilling participants.

Thanks all

 

Glad you got it out!