Intermediate shaft came out attached to disconnet assembly

[Beamer]

I was removing my broken 4wd disconnect assembly and the intermediate shaft that goes thru the oil pan came out attached to the disconnect. I tapped the end of the shaft and it came out of the disconnect assembly. I am not sure if the intermediate shaft is going back in all the way. I put everything back together, but the CV shaft will not go in all the way (it stays out about 1/2").

My fear is something fell off or is not aligned in the front differential now. Any chance something fell out of place? I removed the diff fill plug on the driver's side and everything looks ok, but I really can't see much.

Hoping for some help before I tear into the front differential.

[ErikSS]

How are you measuring your 1/2" out with the CV shaft? I haven't that apart but I've seen diagrams. It seems more likely the spring clip is resisting going into the diff would be more likely than anything to fall out of place.

[Beamer]

Intermediate shaft stuck with 4wd disconnect.


Shaft back in place looking from passenger side.


Looking up from the bottom.

[Beamer]

The 1/2" I am talking about is the gap between the tripot housing and the seal face of the disconnect assy. There is visibly 1/2" of the cv shaft from the seal face to the disconnect. I didn't take a pic before I took it back apart.

I am hoping it is just the clip, any advice on how to push the tripot housing in harder or hit with a hammer without damaging the boot or the housing?

[Beamer]

The new disconnect went on all the way, the cv shaft went in and I was able to connect the Upper control arm to the UBJ. That is when the tripot still has the 1/2" gap.

[Beamer]

I put it all back together, here is the gap that I am refering to. I really hope it is just the clip, but I don't know a better way to push harder or hit the tripot to get it in all the way.

[Beamer]

I just slid the disconnect with the cv shaft in it as pictured above away from the oil pan and the cv shaft did not go into the disconnect any further. I think this means it is not interfering with the intermediate shaft, I just need to get more midevil on getting past the c-clip.

[Beamer]

Figured out how to safely hit on the tripot. Used a prybar to catch on the groove on the outside of the tripot housing, the sharp edge of the prybar catches the edge of the groove and a few good hits with a 2lb hammer got it home.

the tools.


prybar on the edge of the tripot groove.


correct gap.

[Trail X]

Glad you figured it out.

What I do, is use the tripod joint as a slide hammer. I hold onto the actual shaft of the CV assembly, and ram it into the end of the tripod using it's slip-yolk functionality in my favor.

[Opeth]

Also helps when you have the c clip facing upwards when you re install the shaft. Just future knowledge.

[v7guy]

I do the same as James. Just slam it on home.

[TBYODA]

Good info when I have to do this work.

[ErikSS]

Also helps when you have the c clip facing upwards when you re install the shaft. Just future knowledge.

Do you mean the open part of the clip facing down?

[Moots1288]

I've never had a problem or even though of what way that c clip faces

Sent from my SPH-L720 using Tapatalk

[Trail X]

Agreed Matt. What difference does the C clip orientation make Cody?

[Moots1288]

Agreed Matt. What difference does the C clip orientation make Cody?

Cause the prying motion is up and the c clip would be facing up.. Making the cv easier to remove?