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Me again, still working on putting my 85 Euro (S2) together. I have overhauled the driveshafts with new bellows grease etc. but I am struggling to assemble the inner joint (diff end) far enough on the shaft. The splines and hub part looked ok before assembly. Coated surfaces with grease but even with socket and hammer I can't drive the joint far enough on to insert the circlip. So far I can just see the edge of the circlip groove but it needs to go circlip thickness further. Is it just a case of thumping it more or is the something I am missing?
Yeah maybe you have some dirt trapped in there. I don’t believe the wsm calls for any grease on the splines anyway but worth checking the manual on that.
Also do you have the cv inner hub flipped the wrong way? Side with the groove faces the output flange of the transmission. Did mine recently - maybe a small tap required but not more than that. Also note that the cage is slightly different on the flange side vs the wheel side too, I was sure to maintain orientation on reassembly. There’s also a Dwayne thread where he talks briefly about putting that hub piece back on the axle.
Yeah maybe you have some dirt trapped in there. I don’t believe the wsm calls for any grease on the splines anyway but worth checking the manual on that.
Also do you have the cv inner hub flipped the wrong way? Side with the groove faces the output flange of the transmission. Did mine recently - maybe a small tap required but not more than that. Also note that the cage is slightly different on the flange side vs the wheel side too, I was sure to maintain orientation on reassembly. There’s also a Dwayne thread where he talks briefly about putting that hub piece back on the axle.
C531XHO, I am putting this out under the assumption (I know, bad idea) that the CV axles in your 85 Euro are similar to the CV axles in my 86.5 US. Please start at post #171 and see how I refurbished my CV axles. There are alot of photos, maybe something will click with you and you can figure out what is going on.
How religious were you with regard to storing the parts sequentially and retaining the orientation as they came off the shaft? As I recall there was a gotcha in there somewhere - not that I had any problem- just a grotty job to get all the grease out.
I suppose it is possible that a sliver of debris got trapped somewhere unlikely though it seems once the grease has been flushed out with petrol or your solvent of choice.
Not sure I would like to whack the thing with a lump hammer albeit one would have to try real hard to damage the thing. Although the horse has bolted from the stable somewhat I made sure the circlip was in place before filling the grease as I recall.
I also used some copper slip grease on the splines to help prevent seizure- not that we get any road salt over here!
Thanks everyone, your comments lead me to the solution which was I had the hub part of the joint on the wrong way around. The WSM is not explicit/not clear for my model year. My car ('85) has the welded joint shafts. The diff end hub has a flat side and a stepped side. Turns out the stepped side has a slight chamfer on the bore which allows it to push deeper against the locating step on the shaft. I had the flat side against the locating ring but this side does not have the chamfer so the hub sits too far up the shaft, meaning the ciclip groove is not accessible. When I turned the hubs around the joints pushed on with finger pressure to the required depth. Very easy...
The only people who do not make mistakes are the one's that do nothing [but talk]!
My favourite one was trying to do the S4 inlet manifold in mid summer's afternoon on a scorching hot day in June. The car port was 3 sides plus roof- concrete-in short it was like a kiln! I finished up just after sunset absolutely exhausted. Tried to start the thing [bonnet up of course] but it would not take. Figured there was something very wrong- got out of the car [my late S4] and I was absolutely horrified- petrol everywhere- I had forgotten to replace the test cap on the fuel rail! I should have known better as I usually have someone start the car for me first time whilst I overlook the engine bay and have a running hose pipe standing by- not on that occasion! I was lucky to get away with it.
At least you got it sorted out- that is all that matters and why we collectively try to help!
What do we think to bonding large end of the bellows to the housing? It's mentioned in the WSM but I haven't seen reference to this in Rennlist threads
10-17-2020, 12:25 PM
Driveshaft assembly problem
