help, think I pulled the inner cv joint out

[PC5505]

I was lowering my 1G GSX(manual) and everything was going well till i got to the last wheel. The front passenger side, I dont think I had the spindle held high enough with the wheel off. The cv joint on the transmission side is disconnected! I cant get it back in no matter what I do. When I pull the spindle out and down its totally out and even though the car is in gear the spindle will turn, when I push it back in the spindle stops turning, but it doesnt feel like it goes all the way in and the spindle is pitched way out on top (positive if you think camber-wise) please help, I have no Idea how to get this back together and my knuckles are bloody from trying.

Edit: Since posting, I went and played with it some more and the half shaft pulled out all the way from the tranny and spat out about a quart of oil, so I'm in even worse shape.

 

[GST with PSI]

Well...

If I remember correctly the inner joint is a Triple Cardin joint. Essentially it has three rollers that ride in three groves, allowing the joint to rotate at any angle during operation. The only thing that actually holds this joint together is the CV boot itself while shaft is out of the car. Take the inner (trans side of the passenger CV shaft) joint and slide it back and forth, in and out. Note the limp action of the joint when not supported. On the end of the splines there should be a snap ring. Make sure this ring isn't damaged or seriously protruding from its groove. It should fit tight enough that it shouldn't come off without pliers. If your snap ring is OK then slide the axle shaft into the trans. Grab hold of the shaft in the middle between both joints. With the inner joint's splined side in the trans, you should feel the middle section and outer joint able to move independently of the splined side of the inner joint. Use the middle section as a slide hammer. Pull out (away from the trans) on the middle section as far as you can without pulling the inner joint's splined end out of the trans. Then you get as far out as you can, quickly as hard as you can push the middle section toward the trans and hit the inner splined joint with the middle section. Give it a few of these and it should pop right in. you should hardly be able to get a thick bladed flat head screwdriver between the case and inner joint when your finished. Oh, and yep, you'll need to refill the trans with diff fluid. make suer the car is level when you do this. Take an allen wrench and insert the hook end into the fill plug hole to ensure proper level. Or, I just fill it until it runs out for time purposes. Either way make sure after filling the trans and operating the vehicle, you recheck the fluid within 10 miles. I guarantee the level will have dropped from when initially filled.

good luck,

 

[PC5505]

thanks, yeah, you're right about the 3 rollers, I can feel them through the boot, I printed a page from the shop manual that shows an exploded view of the whole thing, so I have some idea of whats going on in there. So I'm wondering, to do all that, is it necesary to remove it completely from the car? Its currently mounted on the ball joint on the lower arm and attached with the brakeline and steering rack. Also, just to make sure, it sounds like you're saying I can do all this without removing the boot, do I have that right? I'm going to give it a shot tomorrow, after work, this things frustrated the hell out of me, so thanks for giving such a good explanation, I really appreciate it since the things currently on blocks in the street.

 

[PC5505]

update: Old addage proves true once more, "if at first you dont succeed, try a bigger hammer." used a dead blow hammer and it went in on the third wack. Just need to figure out what fluid I lost and where to pour it back in I guess, then test drive

 

[Auto RS T]

The fill hole is under the passenger side shift cable. You then remove another bolt from the front of the trans directly below the fill hole. Fill the top hole until the fluid starts to come out the second bolt hole. Then put bolts back in. Tranny should be good to go.

 

[PC5505]

awesome, I'll stop and pick up some gear oil, My manual says what type to get, so hopefully I get that done tomorrow and then I can start worrying about putting on my camber kit and an alignment without any other mishaps.