FL400 Axle Removal
1. Buy a manual and read the instructions thoroughly.
2. If the manual instructions fail then take the inner CV joint a part in the car.
3. Now I like to use a bearing knife (
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=3979) to secure into the groove that is intended for the boot. I then bolt a crows foot (
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=37824) to the bearing knife. If in your case the bearing knife slips off to readily use two muffler clamps mounted 180 degrees a part. Drill a hole in the side of the muffler clamp that a 3/8 bolt will go through and connect those to the crows foot puller.
4. I then connect a minimum 5lb slide hammer to the assembly and give it a few tries. If it doesn?t come right out I will spray some Pblaster in and let it soak for an hour or so. I then will try again with a little more robustness if it still does not free I resort to bertha.
5. Bertha is a piece of 1? pipe that I slide a 10 lb iron weight to and then secure that to the previous assembly. And give it a whirl again if this all fails then I go to what I call drastic measures. Bigger slide hammers can be rented as well.
6. Remember patience and Pblaster soaking does help along with air hammer vibratory cycling.
7. If everything fails I built a drill guide that fits in the CV cup and guides the bit down the center of the axle shaft.
8. After drilling the center out with a 3/8 drill bit I use a long hardened rod to then directly drive on the opposite side axle. Again Pblaster along with air hammer vibratory cycling helps as well. After I get the first side out I machined a piece that fits inside the splines and I butt that up against the shaft left in the car and give a few good swats and it usually will pop right out.
9. Remember to use plenty of anti seize when reassembling.
