2000 Ford Escort ZX2 130000 (CV Shaft Reinstallation issue)

Tiny
JKEPLER
  • MEMBER
  • 2000 FORD ESCORT
2000 Ford Escort ZX2. I began replacing my passenger side CV shaft. Although it was not necessary, I also removed the halfshaft that the CV shaft inserts into. (The book indicated use of prybar if you are not removing it and I didn't have enough space or strength to use a prybar to separate the two) For some reason, this other halfshaft will no longer reinsert back into the transfer case. It goes in far enough to just touch the splines, but no farther. No visible obstructions or damage are visible or "feelable" on either piece. Is there a trick to aligning them? Do I need a special tool to press it? It pulled straight out, no problems. I did not remove the driver side shaft. Help!
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Tuesday, August 29th, 2006 AT 2:25 AM

5 Replies

Tiny
SYNCRAIT
  • MECHANIC
  • 235 POSTS
Inside the transfer case is usually a retaining clip that you need the splines to get by and its done usually by force you need to shove the shaft in and you will feel it go in but it usually takes a few tries because the splines need to line up at the same time. Good luck :)
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Sunday, September 3rd, 2006 AT 8:39 AM
Tiny
JKEPLER
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". Inside the transfer case is usually a retaining clip."

No dice. The 2000 Escort has a circlip, but the ZX2 is bolted in place by a bracket on the differential shaft. I'm starting to feel a bit stupid, but I can't see any reason why the thing just doesn't go in.

Any other thoughts?

Thanks,

jkepler
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Sunday, September 3rd, 2006 AT 11:52 PM
Tiny
NOS
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  • 320 POSTS
When you pulled the old one out was there a clip out on the outter end of the spline? Dude the only thing I can think of is that they possibly gave you the wrong shaft. Several things count splines check the dia. Hold up to the other one and check to see if all is the same if it is set it up in the splines put the nut on the end so you don't mess up the threads and tap on the end with a rubber mallet or a brass hammer sometime the splines get burs on them. Hope this helps.(NOS)
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Wednesday, September 6th, 2006 AT 8:08 PM
Tiny
JKEPLER
  • MEMBER
  • 3 POSTS
The differential halfshaft is the one the factory put on - I pulled it off (it is much easier to insert the new CV shaft if you pull off the differential halfshaft), but did not feel the need to replace it. The problem was the outermost portion of the splines (the part farthest into the transfer case when it is installed) they were worn slightly, but enough to make it hard to pull. 5 minutes with a file and the thing went in fine. (The portion of the splines that actually touch inside the transfer case were not filed)
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Thursday, September 7th, 2006 AT 6:27 PM
Tiny
NOS
  • MECHANIC
  • 320 POSTS
Thats cool, it realy didn't sound like it was too bad have never realy ran into too many problems with thoes. Congrats :lol:
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Thursday, September 7th, 2006 AT 6:46 PM

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