1990 Geo Tracker 2dr 4x4. 
I'm replacing my passenger side CV axle.  I already got my old one out, traded it in under warranty, and began installing the new axle.  It appears the groove on the outside stub axle (hub side) is cut in the wrong place, and I couldn't get the C-clip on because it didn't have enough clearance.  No way was it going to fit.
So I began to remove the axle to go trade it back in for my old one that I KNOW will fit, only to find that now it is STUCK in the housing.  That inner snap ring is doing its job way too well.
I tried prying it only to keep messing up the aluminum housing even more.  I tried hammering it to jar it, and more prying, no luck.  I tried slamming the CV axle itself in and out (using it like a slide hammer) and no luck.  The damn thing won't budge at all.

I'm fresh out of ideas and the last thing I need is to break something and now I'm responsible for it.  Thinking about towing it to a mechanic and having the auto parts store foot the bill for selling me a part with "improper fit."


Any ideas?  I need this out ASAP and running out of time.

I had this same problem with a long side GV axle, I was robbing for the 26 spline
axle shafts, and the only thing I could do was beat the living $#!+ out of it until
the snap ring broke/sheared off

I'm afraid you might need to do the same, unless you want to drop the axle and
remove the long side and try to beat it out with a long rod thru the diff

Or you could separate the cup from the half shaft and take that in with an old
cup/stub shaft on it instead............. just some ideas

Wild

Is there any way the snap ring would fall off inside the diff?  Cause that'd really be a pisser

Yes it could very well fall inside the diff, right in with the spider gears
and could do some damage to the gears as it's sort of a hard spring steel

Wild

Try a chisel or screwdriver or something tapered that fits between the inner CV and rear housing and tap it in. Then get another for the other side and start taping both in evenly. You can apply a lot of pressure evenly like this and something will give. If the ring falls in you should be able to pick it out with a magnet.

If the ring falls in you should be able to pick it out with a magnet.

That's what I was thinking...

Tried hammering on the cup to jar it.  Tried prying evenly on two sides.  Tried tapping a wedge in but only on one side, I may have a helping hand tomorrow to help do two at once.

Wildgoody I do like your idea about removing the long side axle.  I realize I'd have to use a U-shaped rod to clear around the pin inside the differential (is there one or two pins?).  How is the driver's side internal shaft held in place?  Snap ring, too? 

The only other option is to remove the whole differential and drop it on the sales counter at the parts supplier Monday and tell them it's their f|removethispart|@cking problem now...and I won't leave until it's fixed...I mean it doesn't help to be an asshole but sometimes you have to be firm with people

The driver side is held in by a snap ring too. and there is only one pin in it. It dont give you much room to get by it.  A 1/4'' extension wouldent even fit through the open the pin leaves open.

You need somethin like this:
http://buy1.snapon.com/catalog/tools.asp?tool=all&Group_ID=16663&store=snapon-store
This one might not fit a TracKick, but you get the idea.

Thanks TopHeavy that's exactly what I was picturing but I didn't know there was an appropriate tool for the job.

My family friend mechanic came over just now with two huge prybars and a BFH and we hammered those prybars in further and further until that damn snap ring sheared off. I couldn t really get any metal pieces out with a magnet but I guess i'll just put it together and call it good cause I don't see anything else I could do about it

Thanks for the pieces of advice. Looks like the old BFH trick worked once again.