Have you access to a welder??
Tack a plate to the end of the sleeve with a tapped hole in the centre to use as a puller to jack the sleeve off the gearbox shaft - obviously you might need to put something to block up the centre hole of the diff so that you have something solid to jack against.

Thanks for that suggestion. I have a small MIG welder so I'll try that when I get chance. Cheers

Well. I've tried welding to it and using a bolt to try and push it out but my welds just aren't string enough and keep snapping. And I'm just making a mess of the sleeve so soon I won't even be able to put it back together and get rid of it for spares/repairs.
Are there any other options?

Just a thought : could you drill a hole from one side of the sleeve to the other and put a strong bolt through it and attach plates either side and then contrive a setup to pull/push the sleeve.

Maybe the plates could form a rectangular U shape and then bolts to push it out.

 Jules

Hi Jules
Thanks for the reply and sketch.
I had thought about drilling through but couldn't figure out what to do then.
I'm going to try the welding one last time today in the cold, hard light of day. If that doesn't work then I'll have a crack at this.
Just bloody typical for me that something that should just "pull out" won't budge!
Thank you very much for the advice so far. Sorry for being such a pain.

I think the only issue with that plan is how to fix the legs of that contraption?

If there is space/clearance, then a slide hammer may be of use? 2014 Freelander 2 TD4 Manual Dynamic
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if you are going to drill a hole for a bolt then you should be able to put a couple off bits of angle iron on the bolt to give you something to attach the puller to and a tube in the middle with a slot cut in it for the puller too push against hope this helps  2009 FL2 S now gone
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Just an update.


Well, had a break over the Easter weekend but back to work today where the car is garaged.
Had another go this morning and this is where I'm at. I've now built a kind of bridge above the sleeve. I've got two long bolts fastened into a couple of the adjacent threaded holes that the PTU normally is secured by. I've got a piece of metal spanning across the top of the sleeve with another bolt mid way which is fixed to the original bracket I've welded to the sleeve. I've them been tightening the nuts on wash long bolt in the hope that this might pull it out but all it's doing at the moment is bending the metal. I may have to make another piece out of stronger metal. Either way it's still not budging!!!
May have to use the services of a mobile mechanic if I get nowhere with this!
All in all, for something that is supposed to just pull out it's causing me never ending headaches and my poor old 90 is getting hammered in the meantime!

Do you have an air chisel? If so then the impacts of that might well get it moving, if you can angle the forces in the right direction. Hyundai Ioniq 5 Ultimate. The family car.
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PK1968 wrote:

Just an update.


Well, had a break over the Easter weekend but back to work today where the car is garaged.
Had another go this morning and this is where I'm at. I've now built a kind of bridge above the sleeve. I've got two long bolts fastened into a couple of the adjacent threaded holes that the PTU normally is secured by. I've got a piece of metal spanning across the top of the sleeve with another bolt mid way which is fixed to the original bracket I've welded to the sleeve. I've them been tightening the nuts on wash long bolt in the hope that this might pull it out but all it's doing at the moment is bending the metal. I may have to make another piece out of stronger metal. Either way it's still not budging!!!
May have to use the services of a mobile mechanic if I get nowhere with this!
All in all, for something that is supposed to just pull out it's causing me never ending headaches and my poor old 90 is getting hammered in the meantime!

Is there room for a slide hammer to fit on your welded bracket

Evening all
Cheers for the replies. I'll try and answer them all now.

I literally only had time this morning before work to make that bracket and give it a try and then had to get ready for work. I did try prising the bracket I welded on with a crow bar while it's under pressure but nothing.
I don't have a slide hammer but I'll look at either buying one or hiring one as I think there should be room enough to use one.
I've got some old angle iron somewhere so I'm going to make another "bridge" part for my improvised puller out of that. Hopefully it will stay rigid and not bend with the pressure.
I've also ran out of gas for my blow torch but I'll get some and get a bit of heat on it too.
Of course, there's always the hope that I'll go in tomorrow and find that being under pressure has forced it out but that would be completely stupid! 🤣

A slide hammer is pretty easy to make. You only need a length of threaded rod (preferably the same as your current push bolt) and a suitable weight with a hole in the middle, an old dumbell weight will work for instance. Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.

Sounds like a plan. I'll have a crack at that. Got some weights around the place. I'll sort out some threaded rod a dbley you know how I get on. Cheers