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2003, S60 - CV tripod (inner joint) stuck in trans

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R

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asg1986
Posts: 101
Joined: 22 August 2009
Year and Model: 945T,244,P1800,S60s
Location: Northern Chicago Suburbs

2003, S60 - CV tripod (inner joint) stuck in trans

Post by asg1986 »

HELP!!! I've encountered the most stubborn CV Plunge Joint ever! This nightmare is stuck in transmission (LH side) and is not coming out. This isn't my first rodeo either-- but this one has me waiving the white flag. It's defeated me and I'm coming to you all for help/advice!

My 1st round of attempts involved: a CV Slider Hammer (with extension); 3 foot prybar, 2 foot prybar, and construction/demolition prybar against the transmission case and the back of the joint. I had a helper too, and I even used a sledge hammer for a little persuasion-- fail. 2nd attempt: I removed the half-shaft w/ tripod, boot, and grease then hammered a cold chisel into the plunge joint housing where the clamp usually holds the boot -- fail. 3rd attempt: I'm getting desperate now, so despite my better judgement I tried doing what I saw in a video on youtube. The video shows a guy working on a XC90 who claims to have "the most difficult CV joint". His technique involves vice-grips clamped to the tripod housing with a chain running between the vice-grips and his jack. He then slides the jack with all his might away from the car and the joint pops out. It worked for this guy, but not me.

I'm even more desperate now and I'm having fantasies of using some MAP gas or just busting the plunge joint housing into a million pieces. So unless someone has some advice this may be the route I go! :evil:

Anyone else been in this boat and have an idea? Here's a picture of the culprit and some of (not all) the tools I've tried thus far.
Attachments
TRIPOD HOUSING.jpg
Last edited by matthew1 on 14 May 2015, 15:27, edited 1 time in total.
Reason: Clarified title - lowercased

JDS60R
MVS Moderator
Posts: 3532
Joined: 21 February 2009
Year and Model: 2007 S60R 2016 XC70
Location: Mount Juliet, TN
Been thanked: 3 times

Post by JDS60R »

Run into this all the time.

Use the vice grip and the slide hammer. ( bolt to tighten vice grip can be joined with slide hammer.)

If this doesn't work then drill ( we plasma) a hole though the cv joint and use a steel rod (bolt etc) through the center and attach to the slide hammer. It will come out. It needs the slide hammer impact to get it moving. the chain and jack don't give it enough force to move.

If its real rusty when it comes out then replace the seal. Penetrant doesn't make it past the seal. If it sat and rusted for a long time I inject SiliKroil under the seal with a syringe contraption (bent turkey injector) I made up.

If you weld and have to return the core then just tack some round bar across the cv and use the slide hammer on that. Then you can cut the tacks and return it.
Retired

asg1986
Posts: 101
Joined: 22 August 2009
Year and Model: 945T,244,P1800,S60s
Location: Northern Chicago Suburbs

Post by asg1986 »

Thanks for your feedback! The car sat all winter as I don't have a garage to work in and was waiting for warmer weather. The RH side was pretty rusty-- much more than any 850, S70 or V70 splines that I recall... Must not get as lubricated as the older models.

I don't know if my OEM slide hammer will thread into my craftsman vice grips-- maybe I'll have to go buy a new/better pair. And yet another reason to acquire a new tool! I take it you've seen the jack method before! When I tried it my vice grips actually took the pulling for a couple of attempts, but eventually (maybe 5th time) slid off.

I do have a Mig Welder. I'm embarrassed to say I've actually had it for over a year, and have yet to use it. This may be the project that brings it into active service. I've only taken a basic welding class and I'm not the best welder (I'm pretty bad actually)! Don't know if this would be the best thing to weld with my limited skills... but desperate times call for desperate measures! I was going to repair my rusty 945 with the MIG to get a better feel for welding.

I'll keep everyone posted when I break the housing or get the shaft out of the transmission! It seems like thoee are the two most likely outcomes at this junction...

JDS60R
MVS Moderator
Posts: 3532
Joined: 21 February 2009
Year and Model: 2007 S60R 2016 XC70
Location: Mount Juliet, TN
Been thanked: 3 times

Post by JDS60R »

This is the perfect place for a horrible weld. Heavy metal will take the heat. Clean off the protective coating and wipe it down with acetone. a little flat piece welded across the opening will allow you to put a rod through it or chain around it. If nervous or short on time just drill it and stick in a bolt.

Wish you were closer. with plasma we put a hole in each side of them ( if not needed for core).

The stick in a bolt ( through the cv) and then connect the slide hammer.

Just in case no one else mentions this - Put the passenger side tire back on and put it on the ground.
It is possible to pull a car off jack stands.
Retired

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