Problem installing passenger front CV axle

[BRNC_4X]

Upon reinstalling the passenger side front axle shaft, I noticed when I pulled back on the shaft to make sure the inner clip set, the shaft comes right out. I took a flashlight to shine inside the housing and it looks as if the inner collar that connects the stub shaft to the outer axle, has slid back a bit. I believe there is a clip on the outer part of the stub shaft that locks into that collar. Is it possible that the collar got bumped back? If so, why would Ford design its that way.
Question:
Will I need to pull the FDU, separate the cast aluminum housing just to reset that collar??

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[Dmorty217]

@BigMeatsBronco @Snacktime

 

[Snacktime]

Your going to have to pull the the intermediate shaft housing. I would unbolt it and try sliding it out. Looks like the clip the holds the coupler is missing or you pushed past it.

@BRNC_4X I think your on the right track.

 

[BRNC_4X]

Just got doing exactly that before I opened your message. I was able to slide the housing towards the passenger side after removing the four bolts. The problem now is that the house won’t come completely off, my thought is the inner bearing is preventing it from clearing. I only mention this as I have to be reapply RTV between the housings. Again, seems like a huge design flaw for ford.

 

[mpeugeot]

Just got doing exactly that before I opened your message. I was able to slide the housing towards the passenger side after removing the four bolts. The problem now is that the house won’t come completely off, my thought is the inner bearing is preventing it from clearing. I only mention this as I have to be reapply RTV between the housings. Again, seems like a huge design flaw for ford.

I can check the workshop manual when I get home... Funny thing was I was reading this exact section this morning. I was a little miffed they didn't cover the specs/rebuild of the M190... It was pretty much throw it away and get a new one.

 

[4XMORE]

Did you use a fresh circlip when installing the shaft?

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