Hey guys....


Chassis: 96 EJ6 Coupe (DX)
Motor: D16Z6 out of Del Sol
Tranny: Matching

I had another D-Series motor in this car previously and axles were in fine. Ripped the driver side axle up in transport / swap / moving. So I bought a new one from local auto shop.

Axle I got was same part number for a 96 EX.

My passenger axle was still the same one i used in my old motor.

Put in new Z6 motor and went to mount in axles. Driver axle has a fat thumb length left, and passenger side is a little less than that.

Tried hitting the hub on the ends with a soft mallet, nothing. Unscrewed the axle bolts and tried to reset.. nothing... the teeth of the spline are definitely seating right because it goes in for a good few inches before it stops as is. I feel it when its not splined right.

Also, when your putting the axle in you literally feel like you hit a wall. it DOES NOT want to go any further.

I know that all d series axles are the same, with a possible exception for ABS axles? Which the EX had i think? But doesnt explain the passenger one not going in all the way unless its hitting the driver axle that is too long?

But its not an open diff so it couldnt hit the other axle....


see..... im confused... help me out guys...

 

if you removed both axles at the same time theirs a chance the gears inside shifted out of alignment.
when replacing axles remove and replace one at a time.(ALWAYS]

 

Well what do you do if you are replacing a clutch?

 

a broom stick or plunger stick of your choice

 

Drain the fluid, remove the axels and tranny bolts as per the manual.
Remove the PP and clutch disc, bearings per the manual.
Align the disc torque to spec and reverse the order per the manual.
It gets no easier than that.

 

Ok so if this is the case, whats the best way to get them back into alignment?

 

Have one person under the car rotating the axle while someone else whacks away at it. I'm a fan of a 40lbs sledge.

 

ehhhhh... that doesnt seem like it will work...any other ideas...

 

Remove the retaining ring and see if the axle goes in further. If it does, then crimp the ring a little more and reinstall the axle.

 

im going to remove the axles and measure the distances on each side of available...

go from there... only way to solve this i think...

 

I had an issue where mine wouldn't go entirely in after the retainer clip.

Solution: Get a dead blow hammer + a 2x4 about a ft long, put it to the edge of the major metal part of the axle, hammer it a bit until it sits proper.

 

Get under the car with a flash light and mirror and have a peek in the differential to see if there's an obstruction before wailing on it with a sledge. And don't wail on it with a sledge. Have an assistant give the axle end a love tap with the sledge while you guide the axle into the diff (be careful not to damage the oil seals).
This could also be a worn pinion shaft (Helm manual says this will cause the axle to either stay stuck in the trans or fall out by itself, not that it won't go in, but still stands to reason that the pinion shaft could be the culprit).

 

The retaining clip was the culprit.... all nice nice now and slid back into place...