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Discussion Starter #1
Hi. I need to service the transfer case (seals, etc.) on my 2006 RR. The transfer case is the Steyr DD295, which RRPhil has written a great tutorial on breaking down.

My problem is that I’m not sure how to separate the front and rear driveshafts from the flanges on the transfer case. I remove the six e-torx bolts and the manual says to compress the cv joints on the shaft away from the case.

I am unable to compress the shaft by hand, do I need to pry the two parts apart in some manner? Is it rusted together and I need to break it with a mallet? What’s the procedure?

The manual just says to compress them but doesn’t say how to do that.

Thanks.
 

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Procedure says as you say.. compress. No tools given. Use necessary force to remove, I suppose :lol:

I'd start with easy pressure, a long prybar?
Service Manual: DRIVESHAFT


Print Date: 3/26/2019​



[h=1]DRIVESHAFT > REMOVAL AND INSTALLATION > FRONT DRIVESHAFT > REMOVAL[/h]CAUTION: It is possible to fit the driveshaft incorrectly. Note the orientation before removal.
NOTE: A small amount of oil may weep from the driveshaft joints during storage. The loss of this oil will not affect the operation or durability of the joint.

  • Disconnect the battery ground cable. Refer to Specifications .WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
  • Raise and support the vehicle.
  • Remove the transmission support crossmember. Refer to Transmission Support Crossmember - 4.2L/4.4L .CAUTION: Mark the position of the driveshaft flange in relation to the drive pinion flange.
    CAUTION: To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.
  • Release the driveshaft from the transfer case drive flange.
    • Remove the 6 Torx bolts and washers, discard the bolts.

    CAUTION: Mark the position of the driveshaft flange in relation to the drive pinion flange.
    CAUTION: To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.
  • Release the driveshaft from the front axle drive flange.
    • Remove the 6 Torx bolts and washers, discard the bolts.

  • Remove the front driveshaft.
    • Compress the joints to disengage the drive flanges.

 

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Since you're on the east coast I would guess that theres a bit of rust holding the driveshaft flange to the transfer case flange, theres a concentric ring in the middle of the driveshaft flange that centers the flange on the transmission flange, and a slight amount of rust in there will lock the two halves together pretty tightly. A few hits with a plastic deadblow hammer, or maybe a wooden wedge between the flanges will break it loose. Compressing the CV joints themselves shouldn't be that hard. but old crusty grease in the splines may take some constant pressure on them to allow the splines to slide over one another so you can pull the driveshaft flange away from the transmission flange..
 

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Discussion Starter #4
Thank you for you comments. I did notice the concentric circle on the shaft to center it on the case’s yoke, hence hitting it on the sides won’t move it, but it will/may break a corrosive bond.

It appears that there is no special technique, so I’m going to put the air hammer on the joint to see if it breaks the bond. Next I will try to jam a firm putty knife between the parts.
 
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