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2004 Dodge Ram Axle Shaft Removal Issue (pic inside)

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  #1  
Old 05-25-2010, 07:07 AM
upNover upNover is offline
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Angry 2004 Dodge Ram Axle Shaft Removal Issue (pic inside)

Click the image to open in full size.
I went to replace my passenger axle shaft and when I went to remove it the shaft inside the differential pulled loose. What now?

Did I damage anything inside the differential? Do I have to open it up and do anything?

Any ideas on how to get the two seperated now? Can I pull the stub shaft all the way out and take it to the bench to seperate them?

I did a search and this was I could come up with.

http://dodgeforum.com/forum/2nd-gen-dakota/238850-2002-half-shaft-replacement-help.html

http://dodgeforum.com/forum/3rd-gen-ram/242966-play-in-cv-joint.html


Thanks
Joseph
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Last edited by upNover; 05-25-2010 at 07:15 AM.. Reason: change text
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Old 05-25-2010, 02:44 PM
PETE_YK PETE_YK is offline
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Pull it all out, you wont damage anything. Your CV axle is held on to the inner shaft by a clip. A good hit with a hammer should crack it loose no problem. You can re-install the inner shaft without taking the diff cover off PROVIDED the clip is still attached to the end. If the clip isnt there you should take the cover off and retrieve it. When re-installing, a firm hit with a hammer will seat to shaft back into the diff carrier.

Keep an eye on the axle seal and o-ring, make sure they stay intact or they WILL leak. All the 1500 rams from 2002 up are notorious for leaky front passenger side axle seals.
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Last edited by PETE_YK; 05-25-2010 at 02:47 PM..
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  #3  
Old 05-25-2010, 09:14 PM
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andrewdains andrewdains is offline
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I had to do both sides for my 06, it was easy cheezy. the Passenger side was a bear though, really should have used a seal remover instead of a screwdriver and prybar....and a lot of penetrating oil.
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  #4  
Old 05-28-2010, 06:49 AM
upNover upNover is offline
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Red face My Solution

Thanks for the input. I could not pull it straight out. The CV would hit the A-arm bump stop. As can be seen in the first picture.

Option 1: drop the differential (7 bolts in hard to get area)
Option 2: Grind the bump stop weld and then re-weld afterwards

I chose option 2. Pulled right out. I also replaced the differential gasket where the stub axle slid into the diff. There is a new part number so I think they upgraded it. I did not have any leaks and hopefully, I will not have any now.

Click the image to open in full size.



Click the image to open in full size.

Thanks for the help.

Joseph
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Old 05-28-2010, 07:06 AM
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weird. Mine pulled straight out, no problems with hitting anything.
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Old 05-28-2010, 01:14 PM
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hynes9000 hynes9000 is offline
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I know on 08' 4x4 the lock gear and a tapered bearing is attached to the output shaft and pulling it stright out would make it drop down in the axle so i had to take the seal and the actuator off to get it and i reassembled it on the bench lol
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Old 05-28-2010, 02:05 PM
98cherryram 98cherryram is offline
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Im glad you chose option 2, its much easier than what option 1 would have been. I had to replace my differential on mine, and those 7 bolts are some of the hardest 7 bolts I have ever had to deal with on anything! The 3 on the very top of it are extremely hard to get, theres no room to do anything, and you have to use a standard socket, nothing else will fit up there.
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Old 11-14-2010, 06:22 PM
BG724 BG724 is offline
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What brand CV axle assemblies did you guys go with?
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  #9  
Old 11-15-2010, 05:31 AM
upNover upNover is offline
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Default My Axle Shaft

I used a GSP Axle Shaft from Advance Auto Parts.
Axle Shaft <-- Click HERE

I know it got bad reviews but if you look closely of the 4 review 2 were from the same person who said

"BOUGHT THESE IN MAY IT IS JULY CV BOOTS ON BOTH
SIDES OF AXLE AND BOTH AXLES (L & R SIDE) HAVE
RIPPED AND THROWING GREASE ON THE FENDER "

Come on everything ripped up?????

The other says something about having to fix splines, sounds like their old one might have twisted the spines in the shaft.




If you order you can get 40% off. Here is how to do it, add the axle then buy something else (to get your total to over $100), add anything else except oil. Then, just enter coupon code BIG40. You can still pick it up in the store, you just have to order it online.

Not sure if you have an Advance near you or not? If not shipping is free (orders over $75) but you have issues with warranty and if it is not the right one, so I would personally not do that.

If you hit any snafuus let me know.
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Old 10-02-2011, 10:56 PM
bigdodgeram04 bigdodgeram04 is offline
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Default need to replace my shafts

How do I remove the intermediate shafts from the front differential?
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Old 10-02-2011, 11:01 PM
bigdodgeram04 bigdodgeram04 is offline
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so What is the easiest way to pull the intermediate shaft outta the differential? and do the just pull out???
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Old 10-12-2011, 09:21 AM
thillhunting thillhunting is offline
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need help i have a 2002 dodge 4x4. my frontend differential drivers side, i guess its called a shaft that fits to the u joint. is stiped out. i pulled the cv axle off.because its striped to. so i could drive with out being in 4 wheel drive any ways i need to know what the part is called and maybe a diagram of how to take off and put back on. the shaft or what ever it called. thanks
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  #13  
Old 11-23-2011, 12:23 AM
Derg Derg is offline
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Default Had the same problem

My half shaft stuck in the axle shaft as well. I pulled them out as an assembly. I chose to loosen up the differential housing rather than breaking off and rewelding the bumper. Of the seven differential mount bolts I took out all but the 2 upper right side ones. the forward one I really loosened up and on the rear one I just removed the nut. This allowed the differential to swing enough out of the way to remove the axles. I took a close up of the axle shaft retaining clip that holds it in the differential housing as others have mentioned you needing to see that it is still in place and hasn't fallen into the differential.
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File Type: jpg right side axle and half shaft.jpg (83.2 KB, 112 views)
File Type: jpg differential side axle retaining clip.jpg (96.2 KB, 98 views)

Last edited by Derg; 11-23-2011 at 12:46 AM..
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  #14  
Old 09-26-2013, 10:41 AM
birddseedd birddseedd is offline
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Gonna try to fix mine soon. going to have to weld flat stock to the end of the intermediate shaft to hammer it out. does not seem to want to come out. I let a little surface rust get on the new shaft. is sanding it off ok or do i need a new one?

thanks for the help

edit: bought a new one. i do not have the tool to pull it out so welding to the end of it i and a sledge is my only option. any advice?

Last edited by birddseedd; 09-26-2013 at 11:55 AM..
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  #15  
Old 09-27-2013, 12:05 AM
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DirtyDodge812 DirtyDodge812 is offline
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I tried that and beat the living **** out of it and even used two fork lifts (one pulling up on the shaft and the other pulling down on the housing) to pull the shaft out and no luck, The single best way to do it is to pull off the diff cover, remove the center pin that holds the spider gears, and push the shaft in far enough to remove the c-clip. After that itll pull right out and you can re-assemble the carrier, and no this will no interfere with the gear alignment. It would actually be a lot easier on the diff than beating on it like I had to, wish I woulda known before hand.
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Old 09-27-2013, 12:08 AM
birddseedd birddseedd is offline
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I know i can do it that way, and if the clip comes off, i have to. but to do it i believe you have to lower the entire diff, not a quick easy job
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Old 09-27-2013, 12:34 AM
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you dont need to lower the diff, you can just take the cover off and work on the carrier while the whole diff is still mounted inside the truck. This way you take the clip off so you know you have it. Its smart to replace the fluid, intermediate shafts and seals while your in there anyways. If your keeping the truck for a while and plan on using 4 wheel drive, then do it right the first time.
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Old 09-27-2013, 08:25 AM
bigdodgeram04 bigdodgeram04 is offline
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Default i used bearing seperator and slide hamer yanked right out

Put bearing separator in groove tighten down attach slide hammer give nice yank it pops out, of course this was after three hours of prying and scratching my head
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Old 10-20-2013, 11:06 AM
dennisleslie dennisleslie is offline
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Quote:
Originally Posted by bigdodgeram04 View Post
Put bearing separator in groove tighten down attach slide hammer give nice yank it pops out, of course this was after three hours of prying and scratching my head

Where did you put the bearing separator? How did you have enough room behind in the inner CV and the housing?

Last edited by dennisleslie; 10-20-2013 at 11:09 AM..
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Old 10-20-2013, 12:28 PM
birddseedd birddseedd is offline
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Cv axle has to be removed. There is a groove on the end of the intermediate shaft about an inch in. This is where the locking clip goes that holds it to the cv axle. There is a special tool that slides into the groove. A slide hammer attaches to that. Is how its designed. I do not want to spend 100 on a tool ill use once so ill just weld a piece of metal to the end and tap it with a sledge. If it doesn't work as it seems it doesn't often, ill remove my plow mount and have to take off the cover.


Next month
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Old 10-20-2013, 12:28 PM
 
 
 
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