C-clip not coming out

macleanflood · Aug 29, 2026

Driver's axle won't move to passenger. It moves a 1/16 but I need 3/16 to pull the clip out

Wacked on the revolution super 35 axle with my dead blow until it split open. Even tried a hit or two with a 3 lb sledge. And gentle prying on the c clip groove.

Tried loosening the carrier bolts.

Nothing.

Do I need to swing to the fences?

-Mac

macleanflood · Aug 29, 2026

Come to the conclusion the splines on the axle are not straight. Graduated to the 12 lb sledge. Within a few thou now but I'm either out of spline or hammer.

-Mac

macleanflood · Aug 29, 2026

C clip is now out and now that the twisted (I assume) splines have been driven into the locker...now I've got hours of slide hammering to remove the axle.

-Mac

NashvilleTJ · Aug 30, 2026

Unfortunately, since it took a 12 pound hammer with full swings to drive the twisted splines in far enough to pull the C-clip, I will tell you there is absolutely no way the 3 pound slide hammer with 0 additional leverage is going to pull it out. It is going to take a hell of a lot more force.

Short of custom building a gigantic slide hammer or some sort, or building a large jig that will allow you to use the force of that 12 pounder in the opposite direction, or building a jig to use a hydraulic ram, I think you may have to start cutting.

It's not out of the question that you may have toasted that axle.

Good luck, Mac. That's a problem with the C-clip axle that I've not considered. But someone must have dealt with this in the past. Mike? @hosejockey61

That'll Buff · Aug 30, 2026

I've seen some people tie rope around the slide hammer and the head of their sledge and swing as hard as they can to try and force the axles out. No clue how well that works but might be something to consider. Be careful though!

Mud Mixer · Aug 30, 2026

Porta-power with the Duck Bill spreader. Use some wedges made from 2x4's to take up the slack.

Mud Mixer · Aug 30, 2026

CMBD · Aug 30, 2026

You cant run something in through the passenger side and beat it out that way?

Different axles, but I have done this before to get broken pieces out.

NashvilleTJ · Aug 30, 2026

CMBD said:
You cant run something in through the passenger side and beat it out that way?

Different axles, but I have done this before to get broken pieces out.

That's a great idea.

macleanflood · Aug 30, 2026

My father in law and I were double hitting the slide hammer with 3 lb sledges. That's probably what broke the flange.

It really only needs to go a 1/4".

I'll see if I have a bar that will fit through the passenger side. Might need to buy something from the steel yard.

Not sure how the duck bill spreader would work. It would destroy the backing plate for the drum brakes.

Also thinking of welding a nut to the center of the axle.

Just got done working on an RV in the woods with a bathtub full of shit.

Back to working on the axle.

Assuming I'm calling Revolution for a new axle on Monday. Possibly getting a master install kit and replacing all the bearings. Probably should replace the ring and pinion...but it's only down one small tooth chunk.

That or buy a 44 or 60. Or a 9 inch.

-Mac

bbaldwin237 · Aug 30, 2026

This one's been on marketplace for a bit. Already got 4.88s but it's a Detroit, not a selectable.

https://www.facebook.com/share/14n1YY25Syf/

macleanflood · Aug 30, 2026

Allah rockbar to the rescue. About thirty hard hits and she's out.

Found the missing gear bolt in the pinion cavity of all places.

As expected heavy wear on the outer pinion race.

And twisterpation on the axle as predicted.

Thinking I'm calling Revolution on Monday and getting a driver's axle, yoke (I suspect it's is spread because the u joint slides back and forth), a master install kit.

I'm leaving the chipped tooth ring gear in for now.

-Mac

GregBelleville · Aug 30, 2026

Are those revolution shafts that you just pulled out Mac?

macleanflood · Aug 30, 2026

GregBelleville said:
Are those revolution shafts that you just pulled out Mac?

Yuppers. Super 35 30 spline.

-Mac

GregBelleville · Aug 30, 2026

macleanflood said:
Yuppers. Super 35 30 spline.

-Mac

You really do break sh!t

machoheadgames · Aug 30, 2026

Were they abused or did they not hold up well? Going to assume abused, but I wouldn’t be surprised if quality is poor these days.

macleanflood · Aug 30, 2026

@sab had a great theory...

Post in thread 'Operation Phoenix'

Aug 30, 2026

macleanflood said:
I've got plenty of video. Problem is going through all of it. Still haven't had a chance to edit Sand Hollow.

Wonder if I could feed all of my footage into AI and have it suggest moments.

No idea. Not too worried about it.

Honestly probably would have been fine with it twisted and not discovering anything.

I was going after a loose pinion.

-Mac

With the caveat that I've little experience with solid axle vehicles (I'm learning as I go), I think all your problems can be explained by you losing a ring gear bolt. If the bolt fell out and found its way to the pinion/ring gear...

-Mac

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C-clip not coming out

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Post in thread 'Operation Phoenix'

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