Front axle disconnect broken housing

[Skyhead22]

What are some methods used to remove a broken axle disconnect housing from the oil pan? The inner housing has broken off flush to the oil pan and the intermediate shaft is in the way to fit anything inside the broken collar to try to cut or release it. I purchased a small snap on slide hammer to fit between the collar and shaft but there is no lip to catch.

[Skyhead22]

Second pic

[Trail X]

This is a surprisingly common issue. You'll likely find some topics if you search. Generally - you have to drill it out. But be very careful not to drill into the oil pan.

[Skyhead22]

Should I dismantle the drivers side and remove the intermediate shaft?

[Skyhead22]

Or does the intermediate shaft have a threaded hole I can pull out with a bolt and slide hammer?

[v7guy]

I could never get a bolt threaded into the intermediate shaft to stand up to a slide hammer.

Had to drill lots of holes and use a chisel to get the rest out over a few hours.

[Trail X]

I don't think you can remove the intermediate shaft from the passenger side as long as the bearing and seal are still in place. I believe there is a shoulder on the intermediate shaft that prevents this.

Removing the diff from the drivers side is a headache, and you can't remove the diff without removing the intermediate shaft from the passenger side first.

[c0a8l0v6i8n9]

Drill holes very slowly until it gets very easy to drill. When it gets easy your drilling into the rubber ring in the disconnect. Then take a screwdriver and start breaking it apart.

[jetrail]

Hi everyone I'm new here, I'm in the same situation as the original person . My axle disconnect has broke off identically, my question is do you drill straight back to break this up and what size drill bit ? . Please any advice or help is greatly appreciated
John

[Trail X]

You'll have to try a few bits to find the right size. Drill straight into it but be careful not to go into the oil pan. You want to simply relieve the radial stress and get the remaining casting to crack.