Broken circlip

[GavinL]

Dismantling the prop shaft to replace the UJs ( both feel a bit clunky), despite freeing the circlips first, the ends broke off both of the circlips on the diff flange. I managed to remove the UJ through judicious use of a cutting disc, but am seeking ideas on how to remove the remainder of the circlips without damaging the housing.

[RobThomas]

If it were me, I'd get a punch and try to form a dimple in the circlip (hard material, though) and then prise it up enough to get something underneath it.

[RobThomas]

Failing that, maybe a tiny weld blob from a Mig so you can get a lever onto it?

[RobThomas]

...also...if you can file away a chunk out of the circlip you might find it easier to fold it out of the hole?

[philthehill]

Instead of a file use a Dremel (or similar) and carefully grind through the circlip and then fold it out.

Did you before dismantling mark the propshaft tube and flange so than when they go back together as was in the same relative position the balance is retained?

[GavinL]

Returned to it after watching Bath lose to Exeter I'd tried the Dremel approach - it was a bit tight to get the disc into the gap. Also tried drilling a dimple to 'lever' it out, but they are a very hard Spring steel, which actually worked to my advantage in the end, as I filed a vee as deep as I could without damaging the housing, then levered the two ends inwards and they snapped at the vee.

Thanks for the suggestions.

[GavinL]

Yes, marked the flange as suggested. I also put a corresponding additional mark on the inside of the flange, as the mark on the flange edge was inevitably rubbed off during handling.

Out of interest if you forget to do this, how critical is it, and is it possible to rebalance / check the balance? I'll be replacing the bearing, and the old bearing had a grease nipple, the new one is likely to be sealed - does this make a difference?

[philthehill]

With the Dremel I was thinking of its use with a small diameter grindstone to cut that 'V' into the broken circlip.
Whilst it is not absolutely critical to get it back as it was, putting it back as originally aligned reduces the possibility of the shaft being out of balance and having to have it professionally re-balanced.
The propshaft can be re-balanced by using a specialist prop balancing company - details can be found in most classic car magazines.