Dreaded driver side Axle Replacement Tips

Post by **cuhfs** » 14 Sep 2021, 17:24

Posting this to help anyone that is considering removal and replacement of the drivers side axle on a vehicle similar to my. 2004 XC70. I've seen it mentioned on many sites that removal on this model can be difficult. Having done driver side axle replacement in the past on C70, XC90, and 850 consider this confirmation this car it ridiculously difficult to get the circ clip to pop and free the axle. . To date I have tried using a Craftsman 5/16 chisel, Pry Bar, Crow Bar, and Axle pickle fork... all with 3lb sledge hammer all with no success. Spoke to the guru's that offered tips like push it in then pop it. Rotate it then pop it. Keep banging the pickle fork. keep banging the chisel... etc...No luck. Any tips to pop the axle please post them here:

Post by **cn90** » 14 Sep 2021, 17:33

I posted the same tricks as you mentioned (courtesy of @jimmy57), turn the axle, tug and pull.
I used a piece of cardboard to protect the trans housing and the tripod and use a cold chisel to tap it gently.
No need for force, it will come out when the axle is rotated at the "correct angle"...

Post by **Blacklab467** » 14 Sep 2021, 19:47

I would agree with cn90, I was apprehensive the first time I tried this job, Its really not too bad. I rotated the axle and used a nail puller pry bar and it came out pretty easy after about 3 minutes. Just be cautious of prying too hard on the transmission housing. Worst case scenario it doesn't come out and you take it to a garage and have them do it.
I have done it 3 times and its really not a big deal.

Post by **cn90** » 14 Sep 2021, 20:53

This is the set I used. Home Depot sells it for $13, I used the largest cold chisel in this set bc it had the correct thickness to wedge in between the trans and the tripod.

As mentioned above, I used cardboard on both sides of the cold chisel to protect the trans and tripod.
Just rotate, gentle tap with hammer, and rotate until the C-clip open end facing downward...

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: Cold-Chisel.jpg (115.75 KiB) Viewed 6544 times

Post by **jonesg** » 15 Sep 2021, 00:43

We disassembled the outer section of the axle from the inner, then clamped onto the cup with vice grips, connected the vice grip to a slide hammer, 2 hits (or pulls) pulled it out. We had spent time with a chisel etc without success.
We had a slide hammer on hand but you can DIY without having to buy a slide hammer by using all-thread rod.
Vehicle was a ford Mondeo which my friend said Ford copied from volvo .
Same as this video shows.

Post by **cn90** » 15 Sep 2021, 03:22

I forgot to mention that I used PB Blaster ahead of time and spray at the top and let it soak a bit.
This is bc the P2 car C-clip is not bathed in ATF (P2 output cup is blind-ended vs P80 cars where the axle end is bathed in ATF) and may be exposed to winter salt...

Post by **vtl** » 15 Sep 2021, 06:20

You may need a larger chisel once the gap widens. Chisel always work, it may even break the c-clip. I even remember seeing a broken axle here on MVS, which is unfortunate, since now the differential has to come apart.

My driver side axle that has been removed for the first time after 10 years in North East, it had that clip so badly rusted and frozen that the axle could not be removed without force.

Post by **cuhfs** » 15 Sep 2021, 17:41

Update: The "cup" like part is Still not out. Used the makeshift / innovative vice-grip slide hammer tool shown in the above video. No success. Will be buying fatter chisels and more PB Blaster.

Hard to believe the amount of time and effort to remove this. Grrrrrrr

Post by **cuhfs** » 18 Sep 2021, 07:28

Update: with more PB Blaster and the new 3/4 chisel. No success. Still in axle hell. Back up plan is to leave the cup stuck in place and replace from there to the wheel, add grease and clamp that boot while cup is stuck in place.

Post by **xHeart** » 18 Sep 2021, 07:47

cuhfs wrote: ↑18 Sep 2021, 07:28 Update: with more PB Blaster and the new 3/4 chisel. No success. Still in axle hell. Back up plan is to leave the cup stuck in place and replace from there to the wheel, add grease and clamp that boot while cup is stuck in place.

Take it easy. No extreme action is needed. Use hammer on pickle fork, rotate a little each time. The axle MUST be free from the wheel hub fully -- cn90 shows way to suspend it over coil spring at the outer cv housing.

ELSE...