I need help REALLY bad!

[WeaponX]

Hi all, it’s been awhile but life has been busy and my TB has been ok up to about a week ago when a bunch of things went but I’ll just focus on my HIGE problem.
I’m fixing my 4x4 disconnect and taking the half shaft out it was so brittle the next of the disconnect came off with the axel, no big deal I knew I could get it off, then the big problem hit.
I continued to take the disconnect of and from it being so brittle it broke off in the hole of the oil pan. I tried chiseling it out and no go, I tried prying it and nothing.
I was told I could run a metal pipe threw from where the other cv axel hole is and pound it out? Is that true? Will it cause damage?
I’m not dropping the pan I’ll go without 4 wheel drive before I do that. Also there is a black cylinder in the middle that is able to move, someone told me to use vice grips to pull that out before I pound out what’s stuck.
I just want to know if it’s a good idea for the pole or if there are other ideas that will 100% work cause I need my truck for Monday and right now the whole front end is ripped apart. Here is a pic of what it looks like now and as you can see I use the angle grinder to cut some of the metal of which worked but left some marks here and there. PLEASE HELP IM IN TROUBLE!!

 

[Mooseman]

We've had this happen here before...

Hard to Remove Front Disconnect Assembly, 2005 Envoy

Hard to Remove Front Disconnect Assembly, 2005 Envoy, Part 1 This is the story of how I fixed my 4WD. I have included mistakes, durations, true costs and suggest improved procedures for future jobs. We learn from everything, and I hope you may gain from my mistakes. My 2005 GMC Envoy...

gmtnation.com

 

[mrrsm]

...and if I had ANY Kind of Slide Hammer Puller on hand with some 10.9 Hard M8 or M10 X 1.0 (or 1.5) X 15-20mm Bolts, I'd Under-Size Drill-Out Three Triangulated Holes well away from the fractured piece of the Crankcase and GENTLY Try some Light Slam-Hammer Work to EVENLY draw out the remainder of the Flange.

Here is YOUR Image with my suggested locations for Drilling, Tapping & Threading in those (3) Pull Out Bolts. If you decide to try this idea (Method) out... Remember... those Three Holes MUST be Symmetrical in between each other to produce an EVEN Pull on whatever left behind is being held tight inside of there:



You can always spray out that adjacent area down on the Oil Pan with Brake Kleen and then lather in a few Tubes of JB Weld if you manage to clear out that hole and then install a New Coupler. Then... Leave everything sit overnight to harden and seal up The Works.

 

[WeaponX]

I’m assuming my idea of coming in threw the whole of the other cv axel when it’s out with a long metal rod to pound it out is not and option? I’m just asking to cover all my bases that’s all and especially since I don’t think I have any of the tools mentioned besides a power screw driver.
I might be that my truck might have to be a 2x4 for awhile but atleast it will function until I can get what I need to fix this mess. Thank you everyone for your replies

 

[WeaponX]

I GOT IT!! After playing a little more with the angel grinder, drill and chisel I got it all out!!! Thanks for all the help guys cause it was a bitch!!

 

[northcreek]

I’m assuming my idea of coming in threw the whole of the other cv axel when it’s out with a long metal rod to pound it out is not and option?

Why not try it if it's doable ? I would think that gentle hammer/rod persuasion might be just the ticket.

I see that you got it...

 

[flyboy2610]

The disconnect tends to corrode itself to the oil pan. If you ever have to remove it again, first use a punch and a hammer and tap on the side of it. Try to get it to move towards the rear of the truck, then tap it the other way. Once the corrosion bond is broken, carefully pry it out of the hole just a little, then tap it back in. Pry it out a little further, tap it back in. Repeat till it's out.

 

[c good]

What a nightmare! Congrats on getting it out. My disconnect is still working but eventually it will need to be replaced I'm sure.

Would it be worth soaking it with some penetrating oil like P.B. Blaster or Kroil occasionally to help prevent this when the time comes?

 

[Mooseman]

I think only when the time comes. If you happen to pull the axle, try to remove it. Best way is to try and spin it in the hole before trying to pry it gently. If it comes out, slather it with anti-seize. While you have it out, before it fails, take it apart, clean out the crap grease and repack with a good synthetic grease. I swear they fill them with bacon grease it's so congealed.

 

[c good]

I think only when the time comes. If you happen to pull the axle, try to remove it. Best way is to try and spin it in the hole before trying to pry it gently. If it comes out, slather it with anti-seize. While you have it out, before it fails, take it apart, clean out the crap grease and repack with a good synthetic grease. I swear they fill them with bacon grease it's so congealed.

If it still is working, can I service it in place without having to unbolt and remove it from the oil pan? I may just do that if so.

 

[c good]

Without....having to remove it from pan

 

[Mooseman]

It's possible but if you can remove it. it's better.