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wheee!

S30 Half-shaft Disassembly and Rebuild

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That is a great trick! I didn't think of that. I saw many videos on pulling the boot over the entire knuckle with a cone, but didn't want to damage the "unobtanium" boots that were in pristine shape. By turning them inside out, it also lets you clean out all the old grease easily. I will try and get a pic of the cut off portion of the funnel I used. Worked super well.

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I mentioned that the boot clamps had not arrived yet in the original post... but having said that, I found the original style of boot clamps and the proper tool for installing them on eBay for about $25. I will post pics of the boot clamp install when they arrive.

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20 minutes ago, Patcon said:

Are the boots unavailable?

No, they are available. But to Canadians, they are almost unobtainable for a reasonable cost. Some suppliers list them, even at a reasonable cost (under $20 each US) but then they want up to $90 US to ship them!!! Canadian suppliers claim no stock and no one can seem to order them. Part number EMPI 86-1164-D is the replacement part. If anyone can order them down south and ship them up... I'm in for a couple! 

Various Z car suppliers have them too, but with small orders like this, it is prohibitively expensive to ship. Most want to use Fed Ex or UPS instead of USPS. When those packages hit the border, they get hit with brokerage and duty and taxes. Duty and taxes I have no issue with, it's the brokerage and document fees that are stupid. I had a $20 item ship to me from the states via UPS and arrive with $64 in fees attached...

Edited by wheee!

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3 minutes ago, wheee! said:

No, they are available. But to Canadians, they are almost unobtainable for a reasonable cost. Some suppliers list them, even at a reasonable cost (under $20 each US) but then they want up to $90 US to ship them!!! Canadian suppliers claim no stock and no one can seem to order them. Part number EMPI 86-1164-D is the replacement part. If anyone can order them down south and ship them up... I'm in for a couple! 

My condolences.

PM me and we can see if I can help

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Mark and I have communicated and will hold off for now.

However I did some looking and it appears Courtesy can get the older boots up to 11/76. I don't know what the difference would be. the later boot shows as NA

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Hi wheee!

I'm doing the same thing as you but I can't for the life of me slide the two halfs back together with all the ball bearing and spacers present.

It will always bind and get stuck. Like some bearings are to big or some tolerances are not quite right. It also took a LOT of force to pull them apart because the bearings with get stuck.

Did yours slide in and out easily? Because I'm starting to think something is not right with mine..

Thnx

Reinier

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It’s all in the grease! Super clean inside the shaft housing first, then the FSM recommended amount of grease as detailed above! You can do it!

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@wheee! how much play is there with it fully assembled?  In essence, how far can I pull shaft apart if I yank from both ends?  If I’m correct, the cap/clip will eventually stop me from pushing it together.

NOTE:  if I remove the cap/clip I can push them together pretty easy.  Pulling them apart is hard but doable until the end of the shaft is inside the case about one inch and then hard stops.

5E753708-6027-46C9-A05F-884D690D688B.jpeg

Edited by wadelester

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There was about 4” of slide in each shaft when assembled. They move slowly and with some pressure when properly greased after assembly.


SASSZ says hi...!

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Thanks @wheee!.  When fully assembled, I can't move it four inches.  I guess I need to take it apart again.  I'm gonna try less grease just to see if that helps.

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@wheee! do you happen to have a pic of the shaft with the bearings all greased and ready to slide into the axle?  It'd be nice to see the amount of grease you had applied before re-assembly.  Thanks for your help.

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No. Not of the grease. If you follow
The fsm, it is not a lot of grease...


SASSZ says hi...!

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The FSM says apply 1.23 oz. to the area shown in the diagram.  The diagram is a bit tricky, but it looks like I apply 1.23 oz. to the entire channel where the balls and spacers go.  I think I likely used more grease than that.  Thx again.

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That sounds like a lot of grease. I used metric amounts as per the fsm.


SASSZ says hi...!

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Thanks for challenging my previous post.  Now I'm not sure what to make of the diagram.  I see .35 oz goes into the grooves, but where do I put the 1.23 oz?

Screen Shot 2020-04-30 at 12.32.09 AM.png

Edited by wadelester

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12 hours ago, wadelester said:

@Reinier did you ever get your half shaft sliding freely?  I’m having the same problem.

@wadelester In the end I got another set of half shafts and rebuild those. They slid together very easy so there was definitely something wrong with the first set.

Edited by Reinier

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I placed the grease along the channel of each groove on the first smaller amount.
Then I placed the larger amount directly below the retaining washer and circlip at the end of the grooves. Not in the boot area.

7f944c7a5225227651e17880a482dc9d.jpg

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