AWD front axle reinstall to front diff - did I mess up?
05-17-2018, 01:20 PM
#1
Three Wheelin'
Thread Starter
AWD front axle reinstall to front diff - did I mess up?
Hello everyone,
In true Jeebus31 fashion, I potentially messed up a DIY - I was removing the driver's side front strut in order to replace my stock springs with Eibach pro kits and I did not unbolt the front axle shaft from the front diff. When I was rotating the wheel carrier out, the axle popped out of the diff. I am not sure if the seal was ruptured - I was able to unbolt the shaft at the front diff, reinsert the joint flange (99733230900) and bolt the shaft back into the flange/diff without much difficulty. I started the car on jackstands and slowly shifted into first without any leaks. Would y'all recommend doing anything else? There is a minute amount of play in the half shafts (on both sides, actually) and the axles spin freely. Of course once I'm done with the springs, I'll test drive and do a more thorough leak analysis...
After that lesson, I was able to do the passenger's side strut in less than half the time.
In true Jeebus31 fashion, I potentially messed up a DIY - I was removing the driver's side front strut in order to replace my stock springs with Eibach pro kits and I did not unbolt the front axle shaft from the front diff. When I was rotating the wheel carrier out, the axle popped out of the diff. I am not sure if the seal was ruptured - I was able to unbolt the shaft at the front diff, reinsert the joint flange (99733230900) and bolt the shaft back into the flange/diff without much difficulty. I started the car on jackstands and slowly shifted into first without any leaks. Would y'all recommend doing anything else? There is a minute amount of play in the half shafts (on both sides, actually) and the axles spin freely. Of course once I'm done with the springs, I'll test drive and do a more thorough leak analysis...
After that lesson, I was able to do the passenger's side strut in less than half the time.
05-17-2018, 01:48 PM
#2
Rennlist Member
Meh, it isn't like these can go together wrong and continue to function without any obvious issues. I wouldn't worry about it until when/if it starts to leak, but I would inspect the area a little more intensively for the first few hundred miles looking for any issue, not just leaks.
Even then just take it apart and replace the seal. You already know how to do it!
Even then just take it apart and replace the seal. You already know how to do it!
05-17-2018, 03:52 PM
#3
Burning Brakes
This happened to me last year on my C4S. I basically ended up taking apart the entire front suspension to get the strut out (I was also installing Eibach Pro-Kit springs). I unbolted the axle from the hub/upright/wheel carrier, but did not unbolt the axle from the front diff. Pulling the hub off the car, I also pulled the axle out a touch.
Put it all back together, drove car to shop for alignment, drove it back home and drove it around a day or two, then noticed puddle of fluid near the front. Further investigation (including removal of some of the front undertray plastic) revealed the axle wasn't fully seated back into the front diff. More manhandling and got it popped back in. Topped up with a bit of gear oil. Not apparent leaks since.
When you do your further inspection, I suggest you remove the front undertray plastic to see. It was difficult to tell just looking from the side whether the axle was properly seated back into the diff. I thought it was and so did the shop, or rather, they didn't notice anything untoward. It took noticing the leak to lead to further investigation.
I also had to buy a massive 3/4" drive torque wrench to get up to the requisite 350 ft lbs (or whatever it was) to torque back the axle nut. My 1/2" drive torque wrench was about 100 ft lbs short.
Put it all back together, drove car to shop for alignment, drove it back home and drove it around a day or two, then noticed puddle of fluid near the front. Further investigation (including removal of some of the front undertray plastic) revealed the axle wasn't fully seated back into the front diff. More manhandling and got it popped back in. Topped up with a bit of gear oil. Not apparent leaks since.
When you do your further inspection, I suggest you remove the front undertray plastic to see. It was difficult to tell just looking from the side whether the axle was properly seated back into the diff. I thought it was and so did the shop, or rather, they didn't notice anything untoward. It took noticing the leak to lead to further investigation.
I also had to buy a massive 3/4" drive torque wrench to get up to the requisite 350 ft lbs (or whatever it was) to torque back the axle nut. My 1/2" drive torque wrench was about 100 ft lbs short.
05-17-2018, 05:54 PM
#4
Three Wheelin'
Thread Starter
Beautiful - thanks for the tips. I did previously drain/fill the front diff so I'm ready to tackle this job should there be any leaks.
05-18-2018, 11:40 PM
#5
Three Wheelin'
Thread Starter
Ok, I double checked everything today when I still had the car up on stilts. I removed the driver's side front strut again, unbolted the drive shaft, and removed the joint flange. The circlip was still attached to the joint flange and I was able to reinsert the flange into the differential. From beneath the car, I made sure it was snug up against the differential, bolted it back to the drive shaft, and again made sure it was still snug. If it starts leaking, then either the seal is failed or I don't know how to turn a wrench (entirely possible).
05-19-2018, 12:37 AM
#6
Burning Brakes
Sounds like you’re in top of things. I actually drove the car around for what must have been 20-30km with the one axle popped off the front diff. It was quite obvious once the undertray plastic was removed.
Last edited by Saaboteur; 05-19-2018 at 01:51 AM.
05-19-2018, 01:11 AM
#7
Nordschleife Master
Man....the projects some of you guys get into with these cars is impressive. I used to do my own wrenching on my earlier sport cars and motorcycles but this car with all its complexities and electronics involved intimidates me. I do the air filters and oil change but that's pretty much where I draw the line.
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05-19-2018, 10:45 AM
#8
Don’t let it scare you. Axle shafts have been popping out of differentials in the exact same way for decades. Not much changes with the mechanicals and the skills needed to remove and replace. The electronics add a bit of complexity for sure, but save for a wire coming out of a shock or strut there isn’t much difference.
05-19-2018, 12:01 PM
#9
Three Wheelin'
Thread Starter
Man....the projects some of you guys get into with these cars is impressive. I used to do my own wrenching on my earlier sport cars and motorcycles but this car with all its complexities and electronics involved intimidates me. I do the air filters and oil change but that's pretty much where I draw the line.