Hi all, thanks for looking into this thread. My brother came down the drive the other day with a niiice loud clickin'. So we determined that it was the CV and proceeded to tear things apart... Well we've gotten this far. The shaft came out of the case instead of separating at the splines... we can not split them at all. Any suggestions?

 

soak it in pb blaster, put it in a vise. beat the crap out of it with a rubber mallet? thats all i can think of. if that doesnt work, try heating it up with a torch.

 

theres an internal snap ring on that shaft into the cv housing, do what wink said, soak in pb blaster for a day or 2.. that amount of rust brings back bad memories for when the splines on that axle shaft wiped out. $500 in aprts later.. apprently that shaft is chrysler exclusive and the half shaft is updated for that axle shaft as well, with a seal, to prevent water contaamination = rust.