Trying to extract the remaining portion of the bolt will be kind of hit or miss. You might get lucky but for me i've never had good luck.

Good news is there is no reason to replace the whole shaft.

You can just replace the outer portion of the axle which can be bought here for example. http://www.partsgeek.com/qblj8ph-vo...f&utm_content=wc&utm_campaign=PartsGeek+ShopZilla&fp=pp&utm_term=Volvo+CV+Joint

Or you can head to the junkyard and take off a used one.

If you get a used one i would buy a front outer CV boot kit which runs about $12 from your local parts store which will come with a new boot , grease and the one time use crimp clamps.

To get the old one off just cut the crimp clamp on the boot which will release the outer joint. Just make sure not to lose the bearings inside. No special tools will be required just some pliers to crimp the new crimp clamp. They have a actual tool to crimp it but pliers work well for me.

 

Thanks for the helpful reply. Leaning toward an entire junkyard shaft, as the outer portion is expensive, and I"m guessing all the reman axles are junk.
So I will have to remove the half shaft from the gearbox. What's the process to get it out? it's the driver side with the cir-clip.

 

If there's any way to weld on a smaller bolt with hex head to it, that's how I normally try to go, then use the hex to unscrew it. Of course, sometime there's just not enough meat to work with for that solution.

 

That's there cheapest way to go if there enough of the broken bolt showing to have something to weld to.

Also re manufactured CV might also be another option as you can get a Cardone brand one which come with a lifetime warranty for around $70 from rockauto.com

 

I have a mig, but the broken portion of the bolt is an inch or more down in the hole at the end of the axle shaft. Makes it impossible to weld something on, and difficult to extract it. I have an empire unit on the way, and I'll hope to find a used oem before the empire fails. Or, maybe if the empire fails, I can take off the outer stub and place it on my original axle?

 

can always do this and replace the whole end piece

i do have one (cv joint end from my 02) if you need it I COULD SHIP CONUS FOR 20 PAYPAL

otherwise just get a used oem or NEW aftmkt SHAFT if you cant get it out

 

Thanks, I may have to take you up on this yet, as my nightmare continues - see below.

 

So, I have the car back together, have the front end aligned, and new tires on the front, and on the way home from getting the tires it's making a nasty noise. It's a higher pitched grind/scape, that only happens on one part of the wheel revolution. It's coming from the driver side. Sounds something like when a warped brake rotor scrapes against the tin dust shield. Only that has nothing to do with it. Two thoughts that I have:
1 Chinese Empire brand axle that I installed is bad from new. (I bought this because I broke the axle bolt off in my original axle)
2 Metal grit from the failed attempt at drilling out and extracting the old broken bolt, somehow got into the wheel bearing.
I don't have any other ideas. It pains me that whatever it is will ruin my one day old alignment. There is no odd feel to the car, just the noise.
In my experience, wheel bearings make a constant noise - not only at a certain part of the revolution like this does, so I lean toward the axle.
Any other ideas?

 

first try this.

spray the top rubber boot with a little white lithium grease/lube. They can make a honking noise on the floor as you steer. Also the strut bearing assembly is culprit.:angryfire:

 

Is it a problem to put the front of the car up on jack stands, and then carefully run it in drive to help me find this noise? My concern is that the hubs will be hanging down at full sag, so would this extension damage the CVJ's?

 

no problem with that,

oh yeah,, double check the dust shield they can be real finicky.