A lot of people looking for this type of video and can not find it . trust me i was one of those people 2 years ago . thanks vary much for doing it . I just by chance stumbled onto it just now July 30 /2023

Just got through my battle with the seized disconnect. I had no power tools except for my m12, 1/8 bit made holes all around, then a 17/64 bit to crack it, and some chisels

I just completed this job yesterday. I didn't remove any other parts except for the wheel and rotor. Removed the outer tie rod nut and the upper ball joint bolt. I had no air tools. After the axle disconnect housing broke, like yours, I pulled the inner axle with a 1/4-20 grade 8 bolt and slide hammer. I then drilled many holes and used a Dremel with a disc wheel to cut a weak spot in the remaining piece of the stuck housing. Finally, I used the slide hammer again with a tip that would reach behind the broken housing. I pulled it out carefully without even a nick to the oil pan. It was tedious! I will note that the installation of the replacement axle disconnect assembly was very tight even with anti-seize applied to the bore. I had to slowly tighten each of the four bolts until it was fully seated.

The disconnect housing on mine did the same thing. The boss broke off in the oil pan. I ended up using a 3/16" carbide ball cutter in a dremel tool and cut a groove into the broken piece to the oil pan carefull not to get into the pan. Took about 1/2 hr to cut the slot all the way thru and then part way thru at the top. I could then use a srewdriver to free up that boss and remove it. Cleaned up what I could with small sanding drum lightly. Put a thin layer of axle grease in the bore and installed the new disconnect. Did not need to remove the intermediate shaft.

This is why people should use copper anti seize when putting external parts together that are machined to close tolerances. They rust or corrode together if you don’t.

Thank you for this video I have the same problem and I'm going to start doing it now 👍

Thanks a million for this video. Mine has been broken in there since winter. I tried a small 2lb slide hammer and not enough ass to pull out that intermediate shaft. Going to pull everything off the front side in a couple days so I can get a 5 pounder on there. Welded up an eye bolt to 1/4 20 thread to pull it out. The real trick is going to be getting the remainder of that snout out of the oil pan with screwing that up.

LIKE where you put the jack stand . I noticed it before you said anything nice

What an epic battle! You are the man! I'm getting ready to change my 4wd disconnector and now I know what the worst case scenario is. You kicked it's azz.

Omg I’m in the same predicament as I type this I’m so glad I found this video, I was going to go about it the same way except I don’t have air tools so I’ll have to try to drill a bunch of holes and chisel it out by hand, what a nightmare, thanks for making this video I almost gave up wish me luck cheers!

Should put a nut on the bolt in front of the vicegrip so it won't slide

Great video. you have a lot of patience. I didn't hear one swear word unless that was off camera. LOL

Going to start on my son truck next week. 😮

Anyone watching to start this job...I would suggest running the vehicle to operating temp prior to starting. May help so you don't end up in this situation. Then take your time prying it out one side then the other and back and forth till you get some moment and just keep after it slowly. Did mine today and that's how I did it and thankfully I don't not end up like this.

I completely understand, not criticizing at all. Just trying to help the next guy. Only can play the cards you were dealt. I live North East PA so I know the pain.

I replaced my axle and hit my hand twice with the hammer…. Still hurts a week later…

Now I understand why a cpuple of friends that work on my vehicle dont really want to replace that seal. I dont have any power tools, but I'll have to takle this job myself so im not having to add the oil in that so soon each time. Something else that I came across last summer when I was leaving my house I heard a big clunk underneath the vehicle but nothing really felt different while driving, But I always curious what that might have been something right underneath in that 4 wheel drive area and the 4 wheel drive works when I used it a couple of times this past winter but I did notice when it's in 4 wheel low. I believe it sort of has a different noise that it makes when I put it into it. I got the 04 Envoy which looks the same.

Had to come back for some more guidance, when assembling it back, do you push the intermediate shaft into the 4wd disconnect first, then mount it, or do you push in the intermediate shaft into into the oil pan, then mount the 4wd disconnect? If you got an idea of what I'm trying to explain