Inner CV Axle stuck to transmission output flange

[SLC98Max]

Car: 2000 Audi S4
Problem: Front Driver's inner CV Axle will not separate from transmission flange (6 triple square bolts have been removed)

I have a 2000 Audi S4 that I am attempting to remove the front driver's cv axle from. The outer end has been successfully removed from the upright/hub. The inner end will not separate from the transmission output flange. The 6 triple square bolts have been removed.

I have searched this and other forums but currently the only advice I have been able to find has been to use a BFH. I have attempted to persuade it out with a 4lb mini sledge, as well as with a chisel biting on the side of the hockey puck like end that mates with the flange. I attempted this until the point gear lube started leaking out of one of the bolt holes at which point I slopped and the leaking stopped as well (most likely compressed the seal to one side, with any luck it will still be ok).

Some background information. The Audi has been subjected to harsh, salty winters in Rochester New York from the previous owner and a harsh winter in Utah by me. Almost every bolt on the lower side of the body has either been seized or had the head snapped off upon trying to loosen it due to corrosion. I have had to cut quite a few off. I am in the process of cleaning her up so hopefully I won't have to deal with this again.

Any ideas on a more clever way of extracting this cv? I have air tools available. I would kill for a b6 style flange right about now. Here are a couple of the links to threads I have read through with similar issues.

http://www.audiworld.com/forums/audi...stuck-2166699/

http://forums.vwvortex.com/showthrea...n-Drive-Flange

http://forums.vwvortex.com/showthrea...e-Flange-Help!

Wish my underside looked like geeky's...
http://www.audizine.com/forum/showth...PDATED-Version

[MacDaddy]

pop out the flange from the tansmission and seperate it on the bench?

[01audia4]

Maybe your just not hitting it hard enough? Don't be afraid to break it.

[SLC98Max]

01audia4, I went at it pretty hard but stopped when the gear lube started to leak out. I am slightly limited in swinging arc due to it being on jack stands. I was hoping someone might have figured out another way or tool for getting it to separate but I may have to go back to beating it.

MacDaddy, my understanding is that there is a bolt inside the transmission that retains the flange. How difficult is it to remove while the transmission is in the car? I am definitely for attempting this if it is possible.

Thanks for the replies!

[landfill]

You can't remove the flange bolt without taking out the inner cv joint.
Just give a good wack with a sledge hammer or air hammer.

[MacDaddy]

i thought they could be removed, didn't know about a bolt.

well then i say soak it overnight with WD-40 or similar and try and get something wedged between the axle and the flange.

if you got air tools, try the air hammer

[pipe7284]

Try this.....leave the triple square bolts off....get on the car turn it on and launch it as hard as possible!!!!....J/k

hammer the shit out of it.

[SLC98Max]

Well it still doesn't want to come off. I am going to try to machine a tool to help get it off. I will let you know if it works.

[landfill]

Did you see if you can get a pry bar in between the flange and inner cv?

[hibiscusS4]

stupid comment but make sure you got all the bolts off i swore i had all of them off one time and come to find out there was stilll one little bastard hidden back there
edit saw you said u got all six bolts out. sorry

[SLC98Max]

hibiscusS4, No worries, this actually crossed my mind and I checked to see that I had six bolts, then climbed under and turned the CV severally times to visually check that all bolts had been removed, and then somewhat neurotically proceeded to check it like 4 more times the other night. Its a great suggestion though, things like that happen all the time as I think we all know.

landfill, I have not tried that, I was worried about damaging the flange but at this point it may be a good idea. I have a spare set of flanges anyway in my spare 01e, so I may end up doing this. I am machining a separator at work and am going to give that a shot but if that doesn't work then I will attempt to pry back the lip on the flange.

I did some more searching and everyone else that has run into this has been able to solve it with a rubber mallet or 4 lb sledge. Not sure why I am having so much difficulty but it is most likely due to me not being able to get a full swing in because the vehicle is not high enough on the jack stands. Anyway I will let you guys know how it goes and thanks again for all of the suggestions!

[zillarob]

Disgruntled ex-mechanic jb weld it on?

The axles usually just fall off, rarely have I needed to employ any additional "persuasion".
Wait until you try to get the center shaft out, that is the fun one

[landfill]

^^^^@zilla yea that's how %99 of them have been for me. This is the 2nd or 3rd post about the inner cv's getting stuck in like 3 weeks.

[zillarob]

Wonder if aftermarket axle and cv od a little on the big side?
Rust is a major issue in this part of the country though, no metal is safe here