Went to change axle today and it is frozen to intermediate shaft. Is it bad if it intermediate shaft came out of differential with axle or is it possible to reinsert it without taking off cover. Should I just buy a new one and will cover still have to come off to install it. Thanks

 

Kev, I think you are not getting replies because your question is unclear, at least to me. I know of an intermediate shaft inside of the transmission housing, but I am not aware of another intermediate shaft in the driveline. Posting a picture would help.

 

no issue with pulling the intermediate shaft out of the transfer case. it is held by a C clip you just give it a slight tap to re install it in the diff.
once out you will likely be able to separate the 2 .
They sometimes need a good amount of hammering to free them.
good luck

 

No it is not an issue if it comes out, but be careful putting it back in.
The shaft is not expensive, so go ahead and replace it. It does wear so not a bad idea to replace it.
You can replace the bearing as it also is not expensive.
But all new "C" clips, don't reuse any.
Definitely, without any doubt, replace the seal, that could be critical since the old one is worn and possible hardening which will wind up leaking. Do it while you have it apart and save yourself a headache.
I just did mine on my 2008 for the second time since 2014.

 

Thanks for the replies bought a new cv axle and intermediate shaft. On the 02 found out you just have to push new one in and it will lock its self back in. On 02 and 03 no seal really to worry about on differential and don't need to open cover to reinstall intermediate shaft. All back together and running. Thanks