2005 Volvo XC90 V8 propeller shaft removal

MrClean365 · Post by **MrClean365** » 11 Apr 2019, 20:21

I've been working on removal of the front propeller shaft CV Joint from car for a couple of days. Finally the entire shaft for the exception of the CV Joint stuck in the angle gear. I can't get the leverage on the CV joint to remove with a pry bar, let alone is there room to swing a hammer. There are two additional (Maybe Threaded) holes on the back side of the angle gear. In my research they are listed in the service manual to be used in removal of the CV joint. States that these are M8X20. However in using M8x20 bolts, the diameter seems larger maybe M9 (know if I can find) or maybe a M10.

Does anyone have an answer? Maybe suggestion or resource.

Post by **jimmy57** » 12 Apr 2019, 07:54

I have gotten these off by putting car in gear and tapping the accelerator pedal to move car. Do it on grass or slick finish concrete. You want a little front wheel slip and the rear AWD system to be triggered. That will put the driveshaft under load and shear it loose from flange. The rear of driveshaft has to be attached as well as the center support bearing.

MrClean365 · Post by **MrClean365** » 12 Apr 2019, 13:36

Thanks Jimmy. Unfortunately I’m well past the point of no return on this project to do that. The entire CV joint from the front separated from the entire prop. shaft, with what’s remaining in the angle gear. I’ll send some pictures out. Best guess is that it’s seized in with rust. I’ve used PB plaster daily spraying on for a week, tried heating angle gear housing, even notching a line in remnants of CV for pry bar leverage with angle grinder. Thing won’t budge or can’t get enough leverage to pry loose. I’ve got the replacement prop shaft ready to go in. Rear dropped out with a wack of a hammer.

Post by **jimmy57** » 12 Apr 2019, 15:19

OK.
Plan b is grind deep grooves at an angle towards rear, free end of grinding disc towards front of car, into the sides of CVj. You want two opposite grooves deep enough for two jawed puller jaws to catch. You may have to used a nut or socket on top of pinion end to give you something for puller center bolt to push against.
Plan c is use mig welder and weld two 8x1.25 or 5/16 coarse or fine nuts to the CVj over the bolt holes. Run a 8x1.25 bolt into the flange from forward side 17 mm or more. alternately tighten bolts screwed down into the nuts touching the flange bolts to push CV off. the flange bolts are to protect the flange threads since the removal bolts are limited to the same size as the flange threads by the bolt holes in CVj.

MrClean365 · Post by **MrClean365** » 29 Apr 2019, 10:00

So, after much debate and careful surgical procession. An oxy-acetylene torch was used to cut and remove the CVj. I'll post pictures of the removed CVj. It was rusted in there bad. I did use anti-seize with the replacement on the front and rear. Lined everything back up and installed new prop shaft. Yesterday installed the exhaust. Went to take for test drive and the battery was dead. So, today we will see if all is good. Thanks for your help @jimmy57.

Post by **edeppauw** » 02 Nov 2019, 17:22

Just finished removing the driveshaft from a 2004 XC70. All bolts came out with little trouble. The front cvj came out using a heavy hammer and block of wood. Rear required more coaxing as the cvj was rusted into the flange of the rear axle. To free things up I used a pneumatic chisel and kept working around the cvj and flange alternating hitting the axle with a piece of wood and 5 lb mace. finally the driveshaft came loose. to get to the drive shaft i removed the entire exhaust system from the turbo back. i will be replacing the rear drive assembly so if the rear flange is damaged it will be replaced. the cvj to flange is a bad design as in the climate in which I run the car we run in a brine solution for 4 months of the year!