HI Everyone,
I am in the middle of replacing the prop shaft on my 2006 S60 2.5T AWD. I took out all the hex bolts at either end, and removed the carrier bearing support, but I am having trouble getting the ends of the shaft to come loose from the output shaft of the transmission in the front, and the input of the Haldex in the back. Anyone with experience doing this job have any tips or techniques to make this easier/possible? I have tried soaking the junctions with pb blaster, and giving them some gentle taps with a hammer ( I didn't hit too hard, so as not to put anything out of round). Thanks in advance for the advice!

 

Air chisel

 

Okay, thanks. I hadn't tried that yet, because I was afraid of putting the flanges out of round.

 

Yous shouldn't be hitting the flanges anyway. You want to hit the joint on the end of the shaft.

 

Yes, I am hitting the end of the shaft. I hit it for two hours yesterday, and it still won't budge. This is really confusing me, because the car only has 120,000 miles, and nothing is even slightly rusty. Are you sure there aren't any other forces holding the end of the shaft into the flange? Since I am not reusing the shaft, today I tried cutting it near the carrier bearing, so I would be able to get more leverage, but no success with that approach. Any help at all would be appreciated; I have been working on this for almost a week, and it's driving me insane!

 

Like I said, an air chisel. I almost always have to use one when separating them. Does the rear flange have the rubber damper? If so, you can't get a good shot on the end of the shaft.

 

Yes, the rear has the rubber damper. Rather a pain to work around! I did eventually get the shaft out yesterday, with some help from my brother. I cut it right in front of the carrier bearing, and got the front half out by putting a bolt through from the back of the flange, in one of the holes that doesn't correlate to any threads, and banging the heck out of that with my 3lb sledge hammer. The back come out with the same hammer and a ball joint separating fork. Possibly the longest repair I've done yet! Thanks for your insight; this is an invaluable forum.