URGENT help needed - front axle shaft seized during balljoint removal- how to remove?

[Justin311]

Please help a newbie! I will be indebted to you and will do anything! I'm not new to wrenching but had never touched a full size truck much less my new to me 2000 7.3 Exc. I bought it needing the front left lower balljoint replaced and after a little research it seemed very straightforward.

Now the excursion is stuck on a jackstand in a place it can't stay, I can't put it back together due to the axle problem, so I can't get it to my shop. I have to fix it today!

Absolutely everything was down to the last step (step 1 in the pic below) - simply "slide" the axle shaft out of the hub/knuckle so you can undo the two nuts holding the ball joints to the axle housing.

Well, the axle is free and slides out about 1/2", then stops. I "lightly" tapped it with my brass hammer - for about 20 minutes. Then I abruptly beat on it. Then I had to get out my 4lb hammer. Absolutely nothing will help me slide it out. Eventually I just removed the 2 balljoint nuts and the knucke is free but still can't remove because the axle will not come out.

Can anybody clue me in what I'm doing wrong here? Please help me get back on the road!!!

(Going to take actual pics, will post shortly, in the meantime here are some to help explain)

got to this step [1]:

Axle only slid 1/2" to here:

cannot get to step [2] here:

Here is how she sits:

Tried every way to force it out, eventually the balljoints gave enough that the axle slid out BEHIND the knucle. Balljoint nuts are free and the knuckle will almost slide out - but axle is keeping it stuck in place.

 

[Justin311]

Well, I got it. Hopefully this thread helps somebody else in the future - my axle seal retaining ring was caught on a "lip" of corrosion (the only explaination I can offer) so it wouldn't slide out, only in. This made removing the knuckle with the axle in impossible with the balljoints in the way. I cut the top of the upper ball joint off, was able to remove the knuckle, then the axle slid out like butter.

I dont know any other way to do it than to cut off the balljoint, made it easy. What a PITA for a stupid little problem :/

 

[NevrKnow]

Glad you got it and thanks for the headsup. May come in handy to someone in the future.

 

[DaveBen]

Next time lease the ball joints in place until you get the axle removed. I have never tried to remove the ball joints until the axle is out. I am glad you got it!

Dave

 

[WD40]

Justin, glad you got it out, just want to say Welcome to SSD.com.
Tell us about your SD. Come back often.
Doug

 

[DaveBen]

Yes, Justin.

Dave