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Old 03-20-2008, 04:35 PM   #11
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I had this same problem with mine last year. I ended up making a horse shoe shaped yoke to attach to a slide hammer. After a couple of very heavy hits, the whole splined shaft within the transmission came out. The spring clip on the opposite of the shaft released before the spring clip within the cv shaft. I about crapped because I feared that if I continued to pull the drive shaft out of the transmission, the differential spider gears would fall off inside the tranny. A good friend of mine works for Allison Transmission and someone he knew there had a complete manual for this transmission. I was able to determine from the prints that the shaft could indeed be completely removed from the transmission without any internal problems. I pulled the whole splined drive shaft out of the transmission with the cv shaft still stuck on it. Then I was able to put the shaft in a vice and finally remove the cv shaft. All of this because the spring clip expanded to much to allow the cv shaft to be removed with "moderate" force. The splined shaft inside the tranny that the cv shaft is coupled to is approximately 24" long, so this shaft with the cv shaft still attached will be at least 36" long.

If you can't get it to release, send me a PM and if I still have the yoke, I can UPS it to you.
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Old 03-20-2008, 07:44 PM   #12
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I finally got this thing off! For anyone in the future who does this be advised the driver'* side axle can be EXTREMELY stubborn. Aslo for future notice it is not necessary to remove the brake caliper, the rotor, or the hub. It does make it a little easier though.

In order to get the thing out I removed the boot from the inboard joint to separate it from the other half.

It is ABSOLUTELY neccesary to separate the ball joint. This is accomplished by buying a 36" wrecking bar at Lowe'* and iserting the end into the little 0 shaped hole on the control arm. You then must pry jump and curse until the thing comes apart or you can use a pickle fork and FUBAR your ball joint boots.

After they come loose you can sit on the wrecking bar to apply leverage and use your free hands to push the strut assembly out of the way and get the end of the shaft out of the wheel hub. Half of the axle shaft is now free and you now have a big grease mess to clean up wohoo!

You can now go rent a FWD axle shaft puller KIT #5 at Checker/Shucks/Kragen/Advance and use the three claw attachment for the slide hammer to pull the tripod/pot whatever it is out. There are three grooves hidden under the boot for this purpose. A couple taps will pull it free or in the case of ZR1*** pull the center shaft out too.

Now it all easily goes back together.

The passenger side is much easier as there is room to tap the back of the cv axle with a hammer. I did that side in about 20 minutes!

Thanks for the help -- now I have to figure out why my car is still vibrating at highway speeds. Probably one of the two accidents ive had in this poor car. Drunk drivers can go to hell
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