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2003 Buick PAU 4t65e transaxle have P1811 code with hard shift decided to try replacing PCS solenoid myself by removing side cover, but while removing stubborn left CV axle with slide hammer and fork the Inner axle (output axle) pulled out with the CV axle. The inner axle spline end has a groove with a painted white square c ring in it, the other end is still firmly attached to the CV axle and while the splines will wiggle they will not separate. shouldn't the CV axle just pop off / disengage relatively easily? Is my differential now damaged? will i now have to take apart the transaxle to reinstall the axle? or has a $50 parts install snowballed into a $3000 transaxle removal and overhaul. I am now in panic mode and any advice would be greatly appreciated.
Based on your description, I'm not sure what pulled out from what.
The entire CV axle assembly should pull out of the transaxle without a hammer and fork.
The entire CV axle assembly (inner end, dog-bone between inner and outer end, and outer end) should stay together at all times and not get stretched out etc.
The outer end might need persuasion (hammer/press/puller/etc.) to pull out of the hub assembly.
Can you post a picture (or a few) of the situation?
Thanks for your reply CathedralCub I apologize for the confusing post last night it was late and I knew i was in a gigantic mess. I am new to forums so I'm unsure how to post pictures but will try to clarify what happened. I was having trouble removing the transmission end of the CV axle assembly that'* why i rented the FWD axle remover tool/slide hammer from local parts store. It is my understanding that a c clip on the transmission output shaft provides some spring force for retention of the CV axle to the transmission and when you install a new CV axle there is a slight pop as you push the female end of the CV axle in and it seats, and vise versa a pop happens as you pry the cv axle off for replacement. I used the removal tool and after a few hits i heard the pop and it was loose so i pulled the cv axle hub (female splined end) out of the transmission case but could not get enough clearance to get it off and moved to the side with only the ball joint separated, so i decided to remove the Strut and Knuckle for plenty of room to work. With added room i Then took hold of The entire cv axle assembly (from most outer male drive spline to the inner end with the female splined hub, just like a new replacement cv axle assembly would come from a parts house).
and begin pulling it out. But to my surprise/Horror the internal transmission axle pulled out as well still stuck inside the female end of the CV axle assembly and left me looking into the transmission internals through the shaft hole. So the pop I hear and thought was the CV axle disengaging from the transmission (as i suspect is normal) was actually inside the transmission differential as the transmission output shaft popped out of the differential. So any insight on the best way to proceed would be greatly appreciated. Thanks again for your reply.
p.*. the cv axle assy and transmission axle (long left side axle) are still stuck togeather after much prying pushing and clamping it will probably require some special tool building and careful wedging to get the splines separated.
carfixer007 thanks for your reply, Obviously i need to align the splines and imagine i can feel this as it starts to engage, but what'* best to compress the c-clip and seat it back into the differential gear, can i push it in by hand, use a soft blow hammer, or brass punch & hammer. i guess I'm asking what level of force is appropriate without causing damage, and is there any measurement for depth from the housing to check that its all the way into the differential ? or is there another way to do it ? sorry for all the newbie questions, unfortunately all of my experience has been with engines this is the first tranny repair i have attempted so everything is new to me and i cant afford to make a mistake. thanks again for your reply
locked up tight wrench, forced over bulge before they will separate considering making a collar to go over bump the set screw it down to push against but the question is, will the shafts be damaged beyond use before the c clip gives up? or will it be better to use as is (CV axle functioning OK)? or option 3 cut cv housing off axle and find a new c clip. splines no rust wobble slightly how it came out
Thanks for the photo posting tutorial now that you have seen it any thoughts p.*. where do you find transmission parts? GM online shows only a few external parts and local parts houses the same.
. . . and to get that shaft out of the half-shaft, you might want to turn the whole thing on-end (with the CV'* down) and spray some penetrating oil into that joint. Let it seep in then repeat a couple of times. Let it sit a while this way, then try pulling it out again.