Boxerworks.com

Ugh. Cut and drill it out; there's got to be a better way than that.

If the axle is already damaged what's to lose by cutting it ?

Issues I see are wheels are hard enough to get out clearance wise without bits of axle sticking out.

Once it's out you could put it in a press which might damage the wheel before it moves. On the other hand the wheel is scrap anyway if it doesn't move.

Can't press anything while the wheels still in the bike, unless the swing arm and wheel are removed together.
Heavy hammer sounds like it might be the only option. It's gonna damage the thread on the axle but it sounds like the axle is toast anyway.

All the options are really unpleasant. Can the wheel spin when the bike is in neutral, if you bang on the end of the axle it will mushroom so it won't clear the hole in the FD. If it doesn't spin then cutting the axle close to the wheel on the left side should allow that piece of the axle to be removed, will the wheel slide off then? If not then you are fused under the hub. Pull the FD and separate it from the axle. Now you have a wheel with a axle stuck in it. I would use a press to press the axle out. If you have to use the primitive Pete method, buck the hub so when you beat on the axle the whole center does flex too much. Of course if it's stuck that bad the hub is toast so a replacement wheel, axle and spacer will be needed.

The axle reduces diameter at the thread. If that mushrooms to bigger than the axle hole in the fd, then...it's stuck.

Before we go to the destructive removal solution lets try this. Remove the nut and the washer behind it, put the nut back on till it is flush with the end of the axle, hopefully you have some clearance between the back of the nut and the FD. If you have a big dead blow hammer good, if not put a piece of wood over the nut where you will strike. Get a friend to go on the other side of the bike and buck (support ) the swing arm by the axle with a steel bar pushing in your direction as you hit the end of the axle. You want to reduce any flex that will absorb pressure as you hit the damn thing.

Your methodology is good jaggara.

Axle needs to move the width of the bearings, then it will slide outwards until the right hand galled part of the axle has to pass through the left bearing.
Hit it with the hammer again until the axle can slide out.
May or may not be a problem to the caliper mount plate.

Remember to order a new axle nut if you use it to drive the axle. If you can get the nut off after mashing it onto the axle. These axles can get stuck pretty tight. dahik.

Might only be one bearing has seized.

Are we missing the edit button?

ME 109 wrote: ↑Mon Feb 20, 2017 12:46 am Are we missing the edit button?

Should be the left of the three or four icons, top right of your post.
I haven't heard what the exact progress is with the axle.