Replacement axle keeps falling out of trans :(

**W30post** · 06-18-2012

I had the axles replaced in my 04, well because my tires were crap and this mechanic thought he saw some movement in the axle while he was under the car inspecting it. I had the car back from him for about 2 months of almost no driving.

Last Monday driver's side axle slipped out fo the trans and coated the bottom of the car in fluid, yeah..... Towed back to him that day. He didn't look at it until Wednesday and ordered another axle. I picked it up Thursday evening and went home to clean up the mess.

Well this morning, 4 miles from my house and maybe 50 miles on the car since the repair it popped out again. He is calling his supplier to see what the deal maybe but man this is getting old.

Anyone had an axle that will not stay in the trans? I have never heard of this and firmly believe the wrong axle was purchased but I am not even sure if they still have mine for reference on overall length anymore.

Just venting guys but this really blows two Mondays in a row and I hate the smell of trans fluid in the morning.

**Scottydoggs** · 06-18-2012

they click real good when you pop them in. never had one pop out.

**BillBoost37** · 06-18-2012

On the driverside the clip that holds the axle onto the output shaft is located in a groove on the output shaft. If that clip is weak, damaged or missing, that may allow it to pull out.

**W30post** · 06-19-2012

Originally Posted by BillBoost37

On the driverside the clip that holds the axle onto the output shaft is located in a groove on the output shaft. If that clip is weak, damaged or missing, that may allow it to pull out.

Clip is in place. Axle will not slide in far enough. Runs out of spline on the intermediate shaft. Is it remotely possible they put this intermediate shaft in backwards when they had it out for inspection?

**Bob Padilla** · 06-19-2012

When installing theses axles, push it in first then turn it a bit each way while pushing in on it. Just my .02.

I've replaced mine at least 3 times and that's what worked for me.

**BillBoost37** · 06-20-2012

Originally Posted by W30post

Clip is in place. Axle will not slide in far enough. Runs out of spline on the intermediate shaft. Is it remotely possible they put this intermediate shaft in backwards when they had it out for inspection?

100% possible and recently happened to a buddy of mine when his trans was rebuilt. But..that would mean that the output shaft was out of the trans, which no one would have any reason to pull it out. Unless it came out with the axle when they pulled the driverside.

**W30post** · 06-20-2012

Originally Posted by BillBoost37

100% possible and recently happened to a buddy of mine when his trans was rebuilt. But..that would mean that the output shaft was out of the trans, which no one would have any reason to pull it out. Unless it came out with the axle when they pulled the driverside.

Thanks for this reply.

Axle was out for inspection when we were chasing a vibration in the car. So yeah it was out for a reason. I believe that is what has happened. It left on a roll-back this morning because I could not be confident enough to make it the 20 miles back to the shop that is working on it.

**BillBoost37** · 06-20-2012

Well the axle is the CV shaft, outter piece. The part I'm talking about is called the output shaft. It runs from the differential through the length of the transmission.

http://www.automaticchoice.com/Catalogue/4t65e.pdf
In the first picture on this pdf, it's the long unlabeled shaft right above the transmission filter.

**W30post** · 06-20-2012

Originally Posted by BillBoost37

Well the axle is the CV shaft, outter piece. The part I'm talking about is called the output shaft. It runs from the differential through the length of the transmission.

http://www.automaticchoice.com/Catalogue/4t65e.pdf
In the first picture on this pdf, it's the long unlabeled shaft right above the transmission filter.

I used the wrong terminology. An internal shaft was also remove to determine if there was warp or twist on it while we were chasing the vibration. I believe it is the same one you point out in the drawing but I was not there when they looked at it. Does it have different length splines on that shaft for either end?

What was the issue your buddy's trans had, axle popping out?

**OH4CompG** · 06-20-2012

The output shaft can't be installed backwards. The splined end for the axle side is too small to even engage the splines on the diff.

**Rico** · 06-20-2012

**BillBoost37** · 06-20-2012

Originally Posted by OH4CompG

The output shaft can't be installed backwards. The splined end for the axle side is too small to even engage the splines on the diff.

Negative Ghostrider... it can and has been done. 2003 SSEi did it and had his axle do the same thing.

OP, have them pull it out and flip it around. The splines are longer on the axle end and shorter on the diff end. When it's in backwards, the axle won't engage the circlip fully. I'm nearly 100% positive this is your issue/fix.

I have everything at the house to be able to show this. I probably should get some pics/vid of the issue. It's real though.

**W30post** · 06-20-2012

BillBoost37, you were spot on. I called the transmission shop around 2:00 my time and discussed this SSEI issue above. The owner of the shop pulled the internal shaft again and measured both ends. Yes the shaft was installed backwarsds on my car. The spline have more length on one end over the other on this trans. He said the axle defineately popped on this time and he was very confident we would not be visiting him again for this issue.

Thanks a bunch for your information!

**BillBoost37** · 06-21-2012

Never a problem. Likely it there's something odd that can happen...it's happened to me or a buddy.

No..I'm not proud of that..just experienced.

**Aeroheadcww** · 10-28-2018

Pretty sure this is my issue on one of TEPs trannies I bought years ago. I think I've been driving it all this time without the clip engaged. My question is, how do you remove the output shaft from the tranny? Thanks!

**Aeroheadcww** · 10-28-2018

NVM I got it, vice grips, pry bar and a hammer, popped right out, and yes it was backwards

**wstefan20** · 10-28-2018

Originally Posted by W30post

Clip is in place. Axle will not slide in far enough. Runs out of spline on the intermediate shaft. Is it remotely possible they put this intermediate shaft in backwards when they had it out for inspection?

Absolutely! I actually did this exact thing and had my axle blow out on the highway and lost all my fluid and instantly couldn't shift. Went through three axles until I finally found out that I had reversed the shaft.

**BillBoost37** · 10-29-2018

FWIW if you pull the diff cover and pop the diff off the shaft with the driverside axle out, the shaft will come right out.

For those of you that got it out without pulling the cover, that's impressive since there's so little to grab onto.

**97gtp01gt99gt** · 12-16-2018

Is there a difference in the 4te65 passenger cv axle Vs the 4te65-hd passenger cv axle changing mines out of 99 gt checked spares non matched believe that they are the SC axles went to a salvage yard got one out of a gt that Axel looked like the spare I had

**BillBoost37** · 12-16-2018

Yes, The passenger side is the one that is different. This is due to the HD differential being larger than the NA. The diff is on the passenger side of the trans.