D35 shaft removal help

MichaelT

MichaelT

Well-Known Member
Joined
Sep 7, 2007
Location
Charlotte
I snapped my driver side shaft in my turdy-five the other day. This is in a '99 TJ. I pulled the diff cover and all of the teeth look fine. Now I just need to get the broken peice out of it. I have never messed with an axle before. I pulled the 2 c-clips out but can not figure out how to get the broken shaft out. Any help would be appreciated. Here is where I am at. Thanks -Mike
 

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I have the driver side wheel off, it just slides out since the axle is snapped but the brakes are still on there. Passenger side is still on there
 
Since this is your first time... Take both wheels off.. You did good by removing the center pin and the 2 C-Clips.. Slide out the good shaft as it will help you to see what a good one looks like... Then you will better visualize what has happened...

Basically with the outer part removed you will need to get the broken inner piece out. You will need to push it out from the inside. If it doesn't slide out easily you can hit it from the diff area, or use a long rod/stick etc slid in from the other/good side to hit it.

Make sure you clean out the debris from the tube clean/inspect your bearing.
 
Since the c-clips are out is the peice just sitting in there loosely? If so I was thinking about getting a rod of some sort with a magnet on it and pulling it out that way. Good idea or no?
 
it might be, depends on where and how bad it broke.. Sometimes they need to be pounded out sometimes they slide out.. How much is missing from the end you pulled out..
 
It looks like it broke close to where the splines are. I have not pulled the passenger side to compare but it looks like it broke on a taper. I am at work now and will not be able to mess with it more till tomorrow afternoon.
 
I've yet to see a broken stub just push back out with your fingers. Pull both shafts, get a cut off broomstick (or a 4' piece of rebar from Lowe's) and hammer it out from the opposite side. Since you grenaded the shaft, you better grab one of those long magnets on a stick as well. After the broken stub is out, run the magnet in and out of the tube. There's going to be a lot of fragments in there.
 
or the other option... Unbolt control arms, disconnect Brake lines and cables, unhook driveshaft and remove axle shaft broken stub piece (along with axle housing). Replace with something worth your time. :D
 
mbalbritton said:
or the other option... Unbolt control arms, disconnect Brake lines and cables, unhook driveshaft and remove axle shaft broken stub piece (along with axle housing). Replace with something worth your time. :D
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Come on Brent, no need to point out the obvious.
 
I wanna put an 8.8 in there but funds will not allow that and I am also building up a k5 trail rig so when that is done the heep will not see much more than a dirt road. If I take all of the gears and what not out will i be able to just put them back in if I am real gentle with them, I don't wanna have to have the gears set up again.
 
MichaelTsoulos said:
I wanna put an 8.8 in there but funds will not allow that and I am also building up a k5 trail rig so when that is done the heep will not see much more than a dirt road. If I take all of the gears and what not out will i be able to just put them back in if I am real gentle with them, I don't wanna have to have the gears set up again.
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There shouldn't be any reason to pull the carrier.
 
OK, So I got the broken stud out (used a clotheshanger to push it out), cleaned up all the debris, and put the new axle shaft in. Now the axles are pushed in too much and I can not get the center pin through. I used a pry bar and tried to move them back but no go. Any thoughts on how I can put them back? Thanks -Mike
 
MichaelT said:
OK, So I got the broken stud out (used a clotheshanger to push it out), cleaned up all the debris, and put the new axle shaft in. Now the axles are pushed in too much and I can not get the center pin through. I used a pry bar and tried to move them back but no go. Any thoughts on how I can put them back? Thanks -Mike
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I'm not sure I follow what you're asking, but could you put the wheels on the axles to get more leverage to pull the shafts out? Or put just the drums backwards with the lugs loose and use the drum as a slide hammer.
 
I'm willing to bet the c-clips aren't seated properly. That would keep the shafts from moving into their proper position.
 
Ah man i hate i missed helping you out bro. Glad you got it taken care of! Ill have alot more time this coming week to work on some stuff Mike... vacation time! woot woot!
 
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