To renew the rego on my TP sedan, I need to replace the passenger side CV joints.

I already have a new shaft complete with CV joints and boots but I can't get the old shaft out.

I've read the excellent posts by Magna Buff and ZOMG. I've also read the Gregorys and Haynes service manuals but it ain't helping.

Following the procedure set out by ZOMG, I have no trouble removing the retaining nut and sliding the outer end of the shaft out of the hub. However I can't separate the drive shaft from the relay shaft either by pulling on it or by levering it.

I've had two attempts so far - had to abandon the first attempt because I was moving house and running out of time. I'm now in Willow Tree in country NSW and had another try last Thursday. Had to abandon that attempt because of rain. My driveway is gravel and the vehicle stands started to sink in.

However I'd been working at it for hours with no success. I don't believe any average person could put much more force on it than I did but it would not budge. I also tried levering it with a big screwdriver but couldn't really get a grip on it.

I intend to buy a pry bar with a rolled heel in an attempt to get a better grip on it and more leverage. Does anyone have any tips or further advice on getting the shaft out?

Also the Gregorys manual talks about a snap ring: "Lever the drive shaft from the relay shaft and discard the retaining snap ring". Then, when re-installing: "Renew the drive shaft retaining snap ring whenever the drive shaft is removed". Is the snap ring inside the drive shaft or is it on the relay shaft? I can't see one on the new drive shaft that I bought.

Any help would be much appreciated as the rego is overdue and I need to get this done pronto.

drain the gearbox and undo the two bolts on the relay shaft
then the relay shaft and cv joint will come out togeather
the circlip/snap ring has somehow locked the CV in solid
then put the cv and relay shaft in a vice and try to seperate the two
may need a hammer

Thanks, Magna Buff. I was hoping you wouldn't say that. It is the logical thing to do though. I will have one more try when I get the pry bar set (eBay mail order) and if that doesn't do it I will take your advice.

TP - remove both shaft and relay shaft from the car. Remove relay shaft. Hammer from inside the support - it has a welsh plug in it, which will let go and push the drive shaft out of the support. Trying to lever at the joint between the support and the drive shaft will only damage the seals, and hammering works, but you are likely to damage the outer case of the inner joint. Hammer away if you don't care.
The shaft that goes directly into the gearbox needs to be levered evenly from 2 opposite sides.

Thanks for the info. Where is the snap ring that holds the drive shaft to the relay shaft? I can't find one on the new drive shaft. Nor can I find any groove to fit it to. Should it be on the inside or the outside? I don't want to install the shaft without one.

the circlip is on the relay shaft

Thanks. I was beginning to get worried.

Same thing happened to me

had to take out the gearbox three times this week and every time
I had to undo the relay shaft and put it in a vice to hit the drive shaft apart

I even put grease on the circlip but it didnt help

what a pain

Yes, I've been thinking you must be sick and tired of taking engines and gearboxes out.

For starters DONT DRAIN THE TRANS< you will lose some fluid, catch it in a tub to save the mess

Remove the relay or intermediate shaft with the joint, hold the intermediate shaft in your hand and five the joint itself a few firm taps with a hammer, it will separate

The greese will not assist as it is the snap ring holding it together

Ok, today I had another attempt and was successful. I didn't have to take out the relay shaft. I bought an old style muffler clamp and clamped that around the end of the drive shaft just before it enters the relay shaft mount. This gave me a flat surface that I could lever against without any risk of damaging the seal. The rounded heel pry bars that I bought on eBay turned out to be unsuitable but I had also bought an almost flat wrecking bar from Bunnings and it did the trick quite easily.

I didn't have much trouble at all fitting the new shaft. Took it for a drive and it is all fine.

Thanks to everybody that helped with advice.