The axle C-Clips on my 03 CVPI seem to have outsmarted me . . .

I was heading home from Christmas dinner, and as I got off the highway, I heard an intermittent popping sound - kinda like popcorn - coming from my rear passenger side tire.
Pulled over, and discovered the inside of the wheel was totally covered with oil.

After searching here, I determined that I'd blown a rear seal, and probably had a bad bearing. Never done anything on the rear end before, but figured I'd give it a shot.

I got the differential cover off and removed the bolt & pin holding the gears in there, but I just cannot seem to get these dang c-clips off.
Everything I've read says that they should just fall off once you push the axles in, or you can pull them out with our fingers, but I'm not having any luck at all. They seem to be caught in the gear.

Is there a trick to this?

Help!

Do you have the brakes off?

After getting the brakes off and diff disassembled I take a hammer and give each axle a good wack inwards and then just slip the clip off...

BTW; you have the crappy 03 rear axle shafts, the axle shafts themselves are going to be shot and need to replaced with the new ones, I believe they have green paint in the center of them.

Yep, brakes are off. I tried giving it a couple good whacks, but it didn't seem to help - the axle just bounced back out that 1/4 of an inch.

It's frustrating because everything I've read says simply "remove c-clip", so I'm sure it's something simple (and most likely stupid) that I'm doing wrong.

Do all the 03's have bad rear axle shafts? I seem to remember it was only the ones made before Jan 03 & my door sticker says March 03

Have someone hold the axles in while you remove the c clips. You may need a screw driver or pick to dig them out.

What are you using to push them off?

I have a two pronged tool the works MINT....

I have also used a really powerful magnet. I just don't get whats going on because they have never given me a problem before.

Big C-clamp. I've used a big ass c-clamp to squeeze the stud end of the axle against, uh, whatever it squeezes against. You may have to crank it down pretty hard.

Easy answer

The ABS sensors need to come out.

Axles are bottoming on the sensors and you JUST can't get the C clip out.

I did not need to remove the sensors on my car but the sensors vary in length yada yada.

With the sensors out the axles will almost touch when pushed in all the way

Magnets & a C-Clamp did it - clamped it down, used the magnet to pull it away from the gear & was able to push the clip right out.

Anything else I should be ready for when I finish the job tomorrow? I didn't notice the fill plug on the differential - will it be obvious when I start looking for it?


Thanks for the help!

Ding ding ding!

I agree. Read that.

Yeah you had to use the c-clamp because you didn't remove the sensors. The plug is on the front of the bell housing on the driver side. You will need a 3/8 ratchet (no box) but it may be covered in rust. Just make damn sure the ratchet is all the way in so you don't strip the head. Blast the plug with a lot of rust penetrating oil just to be safe.

fill plug is not on the cover, it is on the housing, facing the front of the car.

here is a picture.
http://www.supermotors.net/getfile/605576/original/dsc09796.jpg

what yr did p71's get abs? i hate that sh$t. the noob said his is a 03? i've pulled axles on 3 cars, always the right, only once did i need someone to push hard on it while i pulled the clip. hope you didn't crush anything.
Why do our axles suck? done 93, 94 and a 99 seal and replaced one axle! WTF????

I see your spider gears are out. Please tell me you don't have a Traction-Lok axle. If you do, have fun getting the spiders to mesh back in.

As for the fill plug, DO NOT STRIP THE HEAD!!!!! If you do, you will need to buy an aftermarket cover to refill. Spray with PB blaster before attempting. Also, if you use a bunch of 3/8 extensions, you can put so many together that they will be flexible enough to use an impact gun. Press hard inwards to keep the square in the head, and give a quick blast. Works every time for me. Discard the drain plug and replace with a new one.

If it really gives you trouble, use a torch to heat around the plug. You may need to turn it a dull read in order to free it. I had an 86 F150 that I had to turn orange to even get it to crack loose.

I cleaned out the square hole for the drain plug with a stiff brush, and then banged the socket extension in with a hammer. Of course, I had to use penetrating oil to remove it!