Hi all, had a disaster while changing a front ball joint. The inner CV joint of the front RH driveshaft seems to have over-extended itself and appears maybe 2" too long now!

I drilled the rivets out of the balljoint and when the last one let go, the strut swung outwards. Now the driveshaft doesn't seem to slide 'together' enough and there's a 'lumpy jump' when turning the driveshaft by hand.

The outer CV joint is fully home in the hub - you can hear it seat on/in the hub so that's not the problem.

Any ideas? Is it worth trying to separate the inner CV joint and see if I can locate its guts correctly?? What's involved in removing the RH driveshaft?

Thanks in advance.

Beyond me that one good luck

I’m on vacation (Holiday if you prefer) so I don’t have access to my computer to show pictures.

Based on your comments I am assuming that you haven’t ever taken a CV joint apart

The short answer to your question is that the Axel shaft engages with a splined flower shaped piece

The shaft should have a C clip on the end that will help to hold it in position

The depth that the shaft engages with the flower piece is around two or three inches

This is behind the boot.

If the ball bearings are still in place you should be able to push the shaft into the flower shaped part
If the balls are out of position then you will need to remove the boot to see what you are doing

Good luck

Paul

Click image to enlarge

Are you sure that the drive shaft is fully inserted into the power transfer unit

If not inserted fully it will be too long

Hi Paul, thanks for your reply. You're correct they I've never taken a joint apart, I've merely seen pictures of a disassembled one.

I think it has indeed popped out as, at one point, when I was rotating it the articulation was limited so they would suggest something isn't engaged/meshed/aligned. I'll see if I can get the shaft off tomorrow and peek under the boot. If it's broke then it's broke so nothing ventured = nothing gained.

Hi Paul, thanks for your reply. You're correct they I've never taken a joint apart, I've merely seen pictures of a disassembled one.

I think it has indeed popped out as, at one point, when I was rotating it the articulation was limited so they would suggest something isn't engaged/meshed/aligned. I'll see if I can get the shaft off tomorrow and peek under the boot. If it's broke then it's broke so nothing ventured = nothing gained.

Also - I'm pretty sure it's fully engaged at the inboard end. I reckon that the inner CV has separated when the strut swung out (the 13mm bolt was still in the outer CV end).

Sorted. Removed the shaft and peeked under the boot. It had just become dislocated when the weight of the strut pulled it out when the balljoint released.
A healthy tap with a large hammer got it back together. Thanks again for your post Paul, enjoy the rest of your vacation.

Excellent result!!!!

Take care

Paul

Glad its sorted, I didn't see your message. Did the same a while back. MY11 SD4 SE Auto

Thanks Jeff, luckily it was the RH side!