Removing a siezed CV joint from a driveshaft

[AndrewSlater]

My restoration continues to progress, although plenty of work on small jobs but not many milestones completed.

I am in the process of refurbishing my driveshafts and my plan was to remove the CV joints, inspect, repaint the shafts and reuse where possible, fitting new boots.
The first one disassembled relatively easily but on the second one I can't get either CV joint off the spline. It moves towards the end but binds, and no matter how large a hammer I get it doesn't want to go.

I only need to get one end off in order to do the refurb.

Just wondered if anyone had any top tips for removal.

Just to say the I have removed the circlip

As always any help much appreciated.
Andrew

[Bruce M]

Clean the ends of the driveshaft splines thoroughly and inspect with a magnifier, looking for any burrs or bumps from a knock.

[AndrewSlater]

Thanks for the response Bruce.

I'm pretty sure that there is some damage to the splines but difficult to tell.
What is a good tool to redress the splines with?

I did try to use a small file for a while, but got the impression I was making things worse.
I'm wondering if a puller would work, or last gasp cut the cv joint off and then try to redress the splines.
Thanks
Andrew

[911hillclimber]

The CV and the shaft are both made from quality heat treated steels so neither will yield readily.
The class of fit is exceptional, almost transitional so parts rust together well...

I'm sure Bruce is right, some local damage from a previous visitor.
If thumping one does not move it then you need a garage press.

Off to a good garage with some notes in your hand.

Once off a good fresh set of needle files will be needed to clean the very start of the splines on the shaft (ie the 'length' before the circlip) and a general good clean of the splines to remove rust on the surface. I find a tool makers scriber ideal for this as they sure are pointed.
Assemble with some light grease.

If you think these are tricky, just try doing the same on some Subaru Impreza CV/Shafts with internal C clips....

[AndrewSlater]

Thanks for the advice Graham.

After a bit more of a faff, I ended up using my puller. Once I took a brave pill and wound it with my full force the joint finally came off.

So hopefully I can clean up the splines and it will be good to go again!
Just need to find a decent source of gaiter kits, as the ones I have just bought off eBay don't fit

In other news I have had my new Superb MkIII for a week now - overall pretty pleased - although the chipped heated windscreen in the first 24 hours was a bit annoying.

[fetuhoe]

What year is the car - hence what size are the CV joints?

There is more than one style of gaiter depending on the CV.

[AndrewSlater]

Hi Chris,

yes I bought the gaiters as they were listed for my '74 911, but they are 100mm diameter not 108mm ones.
I think I have the correct ones on order now - so fingers crossed.

Thanks
Andrew