How do you get the broken part of the cv shaft out of the front differential? It snapped fully insides front diff and I have know clue how to get it out. Thanks for the help.

you might want to post pics to help with a better idea of what the problem is.

here the photo!

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here a side by side comparison.

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I've read about others having the same issue. If I remember correctly, they drilled and tapped the end of the axle, screwed in a bolt, and pulled it out. Sounds like a major pain. What brand axle was this?

Hmmm that is a pain. But they are the stock toyota axels actually!

that sounds like a decent option

When the CV breaks at the inner axle shaft extraction or teardown are the two options. The broken shaft in inaccessible by simple measures.

-Jack and support front end safely

-Remove tire, damaged CV and shock assembly (Plenty of write-ups on CV removal)

-Mark and indent center of broken shaft

-Wedge paper into the bottom of the housing to catch metal shavings

-Make sure your drill fits into the tight space at a straight angle. If the drill does not fit removal of the LCA is required. The DeWalt I used was big and had to be operated upside-down to get a straight line on the shaft

-Use a 5/16 cobalt/tungsten carbide tip bit for drilling. Drill a pilot indention with 4WD disengaged to spin the shaft and center the hole more easily

-Engage 4WD and front locker and drill approximately ½ inch deep

-Start the 3/8 tap by hand and continue with a wrench. Back the tap out every so often to clean the threads and clear metal particles, wasted gear oil will assist the tap

-Thread the 3/8 bolt and remove the shaft with a slide hammer. The Harbor Freight model I used was 3/8 and threaded directly into the shaft. Otherwise use a 3/8 bolt and slide hammer jaws. (in the tools pic note the shaft piece at the end of the slide hammer)

-Thoroughly clean the housing to remove any shavings/debris

-Change the diff fluid and check the drain plug for metal after a few miles if need

I would just weld something too it, or is that looked down upon for some reason?

I just want to give a big shout out to TBuzz for all the help today helping me drill and tap the little part of my cv axel out of my front differential. Long day I really hope to never snap a cv inside the front differential ever again!!!

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rep @TBuzz for helpin out a bro

Pull the other side CV and knock out the broken part from the opposite side with a long bar or screwdriver.

i would have just cracked open the clam shell.... wouldnt want any of the shavings going through the gears.

That would work, but I don't know how you'd get a welder on it. The shaft snapped inside the diff itself.

Way to go, TBuzz.

Not by me. I've used that method several times, and also suggested using it on this forum.

Hit the end of the broken axle shaft with some brake clean, tack weld a bolt to it, attach a slide hammer, and pop it out in under five minutes.

The quick tack weld doesn't produce enough heat to damage the oil seal, and it's a lot easier than drilling and tapping.

Of course it does require a welder, which not everyone has.