Need help ASAP with diff install!
Thread Starter
Burning Brakes
Joined: Nov 2004
Posts: 961
Likes: 0
From: Albuquerque NM
Need help ASAP with diff install!
I'm in the middle of installing a new (reman from a reputable performance manufacturer) 3.90 diff and am having problems. The passenger side axle shaft slid into the output shaft after MUCH work, but the I can't get the driver's side to go past about 1/4" in. Any ideas or similar problems out there? Also, the driver's side output shaft has about 1/8" play side-to-side and in-out, and when it's moved has a clanking sound. I'll call the manufaturer tomorrow, but need some advice from the experts on CF. Thanks!
Melting Slicks
Joined: Nov 2004
Posts: 2,592
Likes: 393
St. Jude Donor 05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15-'16-'17
I had the same problem with mine. I seem to remember there is a snap ring or something on that shft. Not sure what it is for, anyway I pulled it out and covered everything with STP and in popped right in . Good luck with this..
Le Mans Master
Joined: Dec 2003
Posts: 5,561
Likes: 448
From: Atlanta metro Ga.
Originally Posted by C6 Z06
I had the same problem with mine. I seem to remember there is a snap ring or something on that shft. Not sure what it is for, anyway I pulled it out and covered everything with STP and in popped right in . Good luck with this..
Anyway, to address the question; try rotating the axle to a different position before inserting. Also, note the orientation of the c-clip. Try to place the open end in the opposite position it is now, etc.
The other issue that will cause some grief is if the axle is sitting at a slight angle when you are trying to seat it. Make sure you hold it level when applying force.
Also, you probably will not get these to seat just by hand pressure, and that's by design.. Get a rubber / dead blow mallet or similar and tap it in.
Last edited by Dan_the_C5_Man; Jun 27, 2005 at 12:04 PM.
Drifting
Joined: Jul 2001
Posts: 1,312
Likes: 2
From: Lake Havasu City AZ
Gd.
I just did this Saturday for the third time. Lube up the splines with
diff lube. Put a floor jack under the lower A-arm and jack it up to
where it starts lifting the body. This will decrease the angle. Get the
axle spline matched up by turning the rotor until you feel them line up.
Support the axle as it enters the diff and using the rotor push the axle
in. You may have to use both hands after it gets started. Clean off all greasy finger prints off the rotor when your done ( then you can blame
someone else if the seal leaks
).
Your output shaft sounds like it has too much play to me..
Mike V
I just did this Saturday for the third time. Lube up the splines with
diff lube. Put a floor jack under the lower A-arm and jack it up to
where it starts lifting the body. This will decrease the angle. Get the
axle spline matched up by turning the rotor until you feel them line up.
Support the axle as it enters the diff and using the rotor push the axle
in. You may have to use both hands after it gets started. Clean off all greasy finger prints off the rotor when your done ( then you can blame
someone else if the seal leaks
).Your output shaft sounds like it has too much play to me..
Mike V
Melting Slicks
Joined: Nov 2004
Posts: 2,592
Likes: 393
St. Jude Donor 05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15-'16-'17
Originally Posted by Dan_the_C5_Man
Err, that snap ring is there for a reason, not to be discarded "just because"..
Anyway, to address the question; try rotating the axle to a different position before inserting. Also, note the orientation of the c-clip. Try to place the open end in the opposite position it is now, etc.
The other issue that will cause some grief is if the axle is sitting at a slight angle when you are trying to seat it. Make sure you hold it level when applying force.
Also, you probably will not get these to seat just by hand pressure, and that's by design.. Get a rubber / dead blow mallet or similar and tap it in.
Anyway, to address the question; try rotating the axle to a different position before inserting. Also, note the orientation of the c-clip. Try to place the open end in the opposite position it is now, etc.
The other issue that will cause some grief is if the axle is sitting at a slight angle when you are trying to seat it. Make sure you hold it level when applying force.
Also, you probably will not get these to seat just by hand pressure, and that's by design.. Get a rubber / dead blow mallet or similar and tap it in.
Thanks for having such a watchfull eye..
I would never have removed the ring although I still have no clue as to why it is there !!!
Drifting
Joined: Oct 2004
Posts: 1,384
Likes: 8
From: Southwest Virginia
I had this same problem when I installed a heavy duty output shaft. The grove where the snap ring sets in was not cut deep enough in the new shaft. 
I had to grind about .008 off the outside of the ring so it would compress down enough for the splines to slide over the ring. If the new diff has a new output shaft then you may want to try to remove the ring and see if the axle will slide in OK without the ring. But as state above don't run it without the ring!
I had to grind about .008 off the outside of the ring so it would compress down enough for the splines to slide over the ring. If the new diff has a new output shaft then you may want to try to remove the ring and see if the axle will slide in OK without the ring. But as state above don't run it without the ring!
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Le Mans Master
Joined: Dec 2003
Posts: 5,561
Likes: 448
From: Atlanta metro Ga.
Originally Posted by C6 Z06
Dan, I reread my post and your are right on your comment about removing that snap ring!!! What I meant to say was that I removed the shaft and lubed it with STP, not the ring as my post implied.
Thanks for having such a watchfull eye..
I would never have removed the ring although I still have no clue as to why it is there !!!
Thanks for having such a watchfull eye..
I would never have removed the ring although I still have no clue as to why it is there !!!
And that ring is a common method of retaining / locating the CV joint assembly to the output shaft.. My daily driver Toyota Corolla’s trans and CV joints are designed exactly the same way. You don't want that CV shaft sliding in and out of the output shaft every time the suspension compresses and extends.. That's what the joints in the CV axles are for.