I have a 2007 HHR LT with 2.2L, automatic transmission. I pulled the drive shaft on right side (passenger) and the intermediate shaft came out with cv axle. How do I remove the intermediate shaft without damaging or marking the shaft. Chevrolet wants $170 for a new replacement shaft. Anyone out there with a good idea or experience please respond quickly. Thank you.

 

The right way to do it is a bearing separator tool.
Another way to do it is to put a 1.25 inch muffler clamp on it then tap on the clamp.

Here is thread with photos:
https://www.chevyhhr.net/forums/prob...d-57383/page6/

 

I tried what DonBrew Technical advisor suggested to no avail. I ended up disbanding the inner boot from cv axle, then cleaned the grease out followed up with a steel punch to the center aluminum soft seal plug dislodging the intermediate shaft from the cv axle after three hits. I saved myself $170 plus several hours of time plus travel time trying to locate a bearing separator and not being able to find an 1-1/4" muffle clamp anywhere. I'm sure I'm not the only person to experience this problem. I plan on rebuilding the shaft if I can find an outer boot that will fit. I believe the hole can be sealed with either JBWeld or a thin narrow aluminum disc on bottom side where intermediate shaft locks in to inner joint housing.

 

My first time, I took it up to the local trans shop and asked how they did it. The guy was a typical guy and just used his bearing separator tool.

You don't use it the way it's designed; you just use it as a place to tap with a hammer.

I'm confused, I thought you were replacing the axle? Pop the extension off of one put it on the other.

 

Replying to Don Brewer comments, I purchased a complete new CV axle not rebuilt and wanted to keep it that way. I plan on locating and purchase an outer boot to rebuild and replace the driver's side if and when it goes out. In the advent when I needed the other on my local independent parts house was closed.