Make sure you use some antisieze when you put it back together . Access to air tools? Maybe air hammer? A little bit of heat does go a long ways. Doesn't hurt to try!

Justin Lauscher said:

Make sure you use some antisieze when you put it back together . Access to air tools? Maybe air hammer? A little bit of heat does go a long ways. Doesn't hurt to try!

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Yeah I'm probably gonna go with heat, it's crazy how seized up this axle is. I beat it with a hammer so hard it started to bend the bolt a little.

The best sold penetrating oil is KROIL which ive used for years with really good luck. Ive been experimenting with a mixture of atf and acetone which has been tested to be the best penetrating oil. You can make a puller out of a donut. You would need to weld a plate (1/2") to the face of the donut that is threaded in the center, put some all thread (1/2-13 at least) thru the hole with a nut welded on the end to drive the all thread. The plate will need to be drilled or cut to clear the wheel studs.

A buddy built a puller like this, used heat, spent about a week working on it and was unable to get the axle out. He separated the cv, pulled the motor, and when he put the motor back in put the cv together under the car. I antiseized my axles 12 years ago and drive the car especially in winter, I can take the axle nuts off and push the cv's thru by hand.

I can almost relate to this TSi, after 4 tranny pulls figuring out clutch issues mine are like butter. Haha

I would take the whole spindle out with the axle and then place it somewhere where it will stay upright and soak the hell out of it with penetrating oil .

I'd just hit up a junkyard or miller import parts for a knuckle

Pull the knuckle take it to a press and press out the axle end. Be sure to clean the hub completely before installing a new axle tho, get all the rust of it.

I have never seen anybody get the axle out of the hub splines when they are frozen like that. I've seen people use heat, presses, etc and have not removed the shaft. Most shops just replace the entire knuckle....lots of money. If you can get to the 4 bolts on the back of the hub, you should be able to remove the hub and axle, saving everything else.

If leaving the castle nut on and clobber it with a BFH doesn't work, get a new knuckle and hub! Best to replace the left and right hub as a pair.