TA22 Diff Removal and AE86 LSD install

[GeneSPIDA]

Hopefully the 5mm can just be taken off the end where the splines are?

[71TA22]

GeneSPIDA,

50mm was a typo. Oooops.

At the time It looked to me like the splines did not go any thurther down the shaft on either axel so I would say there will be plenty enough even with a few mm taken off.

[GeneSPIDA]

OK. Today, I'm going to pull an axle out of the diff on the car just to make sure it's exactly the same as the donor axles if I have to have them shortened slightly.

I'm going to check how things fit together on the donor diff too. But I think 71TA22 is right. Looking at how a clutch LSD seems to work, the side gear probably does move as the clutch grabs and lets go, so there probably is a need for a bit of space to prevent pressure.

Anyway, I'll see how I go today, and will probably end-up taking the axles out of the car down to get "trimmed".

BTW, here is a link to some useful AE86 LSD diff diagrams:

http://homepages.ihug.co.nz/~stompyz/lsd_rebuild.htm

Gene

[GeneSPIDA]

Well, progress today was a little slower than expected. As experienced by some others doing this type of thing:

1. The diff filler plug was burred and didn't want to come-out (23mm) and I only had a 22mm and 24mm socket.

2. The passenger side axle refused to budge.

Solution:
Off to the shops to buy:

1. One 23mm socket
2. A bigger hammer
3. A replacement filler plug for when I get the damn thing out.

Let's just say the socket and big hammer worked. And I'll be using the new plug when I put it back together.

Other than that, I think I have to accept that I should shave 5mm off the axles as 71TA22 has indicated. A bit more research and another page on the web regarding AE86 LSD's and axles from non-LSD diffs:

"Aftermarket supplier LSD (KAAZ and Cusco) will accept both and is built with enough clearance to cover for pinion offset differences as well. Interestingly enough, OEM (race version) TRD 4 pinion units did not clear the longer axles. The axles should be shaved about 5 mm in this case to fit correctly"

The axles out of my TA22 were exactly the same as the donor diff, so Matty's diff must have been out of a TA22 as I originally thought. I'll take mine somewhere next week to try and get the 5mm taken off.

Some more pics of SPIDA with the axles removed.

Still.... shouldn't be a problem getting it all working.

Gene

[TA22 GT]

Yep you need to take 5mm off each axle. I've done this in the past for a T series TRD LSD into the stock housing.
I took 5mm off to make enough clearance, this is fine and still leaves enough spline so there are no issues.

Hope this helps,
Simon

[GeneSPIDA]

Thanks Simon.

How did you get the 5mm taken off? Did you take it to a diff place and have it just cut or lathed off? Or do it yourself?

I presume that was when you were over East?

[71TA22]

Gene,

I pulled one of my axle's anyway to check that my memory had not gone. After a while you start second guessing yourself.

Anyway the LSD axle is 4mm shorter than a standard axle. Rear of axle flange to end of axle shaft 650mm against 646mm.

LSD axle is on the right on photo below:




For those that want to take axle shafts out:

Must put the rear up on axle stands. Undo axle backing plate nuts - 14mm socket.



Use old steelie (with wheel nuts done half way) as puller. Short sharp pull and the axle is out. Do not bolt right up and try to pull as you will just pull the car off the axle stands.



Grease rim of diff flange oil seal. Put axle back in and tap in with wooden block until bearing seated. Redo backing plate nuts and torque to 5Kg/m.

[GeneSPIDA]

Thanks Mike,

Appreciate all the help and effort you've gone to. That's pretty conclusive evidence

Off to the axle choppers

Gene

[71TA22]

Gene,

Thats ok. Putting the photo's up took longer than axle shaft out and back in.

[GeneSPIDA]

Mike,

Curious, did you have to drain the diff oil just to remove the axle or can you take the axle out without the LSD diff oil "escaping"?

Just curious because so far I've drained the oil first. But since I'll be waiting on the axles when I put the centre in, I thought I'd need to leave the oil until the axles are in. Or am I mistaken (AKA stupid)?

Gene

[71TA22]

Gene,

No need to drain the diff oil as the diff flange oil seals hold it all in (unless diff is overfilled). Just be careful not to damage the diff flange oil seal when you remove/replace the axle shaft.

Its best to put some grease on the oil seal lip before replacing the axle shaft. Minimises chance of friction damage to the oil seal when you set off in the car and before diff oil has had a chance to work its way round.

[GeneSPIDA]

Geeee, goes to show how observant I am. When I took the axles out of my TA22 yesterday, I compared the first one I took out with the 2 out of the donor axle. Yep, all the same length. So, being out of non-LSD diffs, I assumed I would need to have the 5mm taken off both of them when today my girlfriend said, "That one's shorter".

What do you know? One of the axles is shorter! Must have been replaced with one out of an LSD-equipped diff? It also has a different coloured wheel bearing - not that that means much.

When I've recharged the camera batteries I'll put up some pics. But I got out the spirit level across the top of all 4 axles (3 exactly the same) and the short one was around 6mm shorter (vernier calliper measured the gap). I measured the length of them at 560mm and 566mm respectively from the top of the wheel bearing. So, I think I'll take 5mm off the longer one as that should be fine.

And it seems I've got my own "sample" to say, "Make it match this".

Anyway, today I dropped the old open centre out and put the LSD one in, so it's all ready and waiting for the axles now

[71TA22]

I measured the length of them at 560mm and 566mm respectively from the top of the wheel bearing. So, I think I'll take 5mm off the longer one as that should be fine.

Gene,

I checked against your measurements and got 562mm and 566mm respectively.

Looks like you are set.

[TA22 GT]

Gene,
Yeah I just cut them myself. Somewhere around 5mm is fine. Sounds like one is already done for you. There's really no reason why you couldn't just cut it yourself and clean the end with a file. Of course putting it in a lathe to machine the end face flat is a neater option. Just don't use a grinder and create too much heat on the shaft as you could damage the shaft by putting too much heat into it.

Cheers,
Simon

[GeneSPIDA]

Here's the pics of the different axle lengths from my car and the donor diff:





And LSD in and ready - not that it looks much different: