091 input shaft removal

[split_trix]

i tried for 2 hours theis morning to remove the original 091 input shaft ready to install rjes subaru shaft. Am i right theat the circlip has to come off ?



what other bits need to be removed ? Number 31 in picture is that threaded ?

tried again, removed circlip, cannot get to part No. 32 hands are just too big, so I assume the diff needs removing/moving... Is this just a case of removing the output flanges and shifting the diff around ?

cheers
chris
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52 vwrx

[doppelganger]

[split_trix]

Its the diff thats was in the 091 box, i'm assuming it's bog standard.... problem is I can't get my hand in there to get a decent grip on No. 32 to slide it.....

will take a pic of it sometime today..

chris
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52 vwrx

[doppelganger]

[split_trix]

Is it easy to unscrew the shaft from No.31 ? why would you need to shorten it ?

cheers
chris
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52 vwrx

[doppelganger]

on mine with a syncro diff ,the angle needed to get in before i could put it on that threaded bit meant the threaded bit was to long.you may not need to but its ok to do it ,a prodrive gearbox builder said so

i also had to slightly clearance the syncro diff as well ,but thats better exlained with pics.
you could of course just move the diff out of the way ,but i was racing the next day
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vwdrc class rep




vwdrc AE bugjam winner
11.23@127mph. 1.47 60ft. 2.85sec 0-60mph

[B4Tfink]

does this help any?

http://www.vwkd.co.uk/bb/viewtopic.php?t=840&highlight=removing+input+shaft

[split_trix]

yeah that helps alot now i know what SHOULD happen..... just wish type 2 boxes had removalable side covers would be alot easier then....

cheers guys
chris
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52 vwrx

[rjes]

Once the circlip is slid along the input shaft out of the way, the splined sleeve (which is also the reverse idler in DK or similar boxes) should slide very freely. If you are lucky it will slide far enough to allow you to unscrew the two shaft halves before it hits the diff. If you are not lucky it will hit the diff while still covering the join between the two shaft halves, and prevent you from unscrewing one from the other. Rotate the diff to see if there are any positions which give you a bit more room.

If you can't slide the sleeve far enough back with the diff in any position, you have no choice but to loosen the diff side nut a couple of turns to allow the diff to drop out of the way. Loosen the one on the ring gear side. To do so you will need to take the CV flange off ant to buy or make a suitable tool. Be sure to scribe a line across the nut and casing so you can put it back in exactly the same place. The VW manuals don't mention that the diff can be in the way.

You shouldn't need to shorten the stud between the two shafts once the diff is out of the way. If you do for any reason, be careful not to shorten it too much so that it can disappear into either of the shafts.
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Regards,

Richard,

R J Engineered Solutions
Quality Subaru Powered VW Components
www.rjes.com

[split_trix]

i got the original shaft out but can't get the new on in..... the thread sticks out of the 2nd shaft about 5mm max, the thing thats seems to be hitting is the slider and the diff when i attempt to screw the shaft back in.

could you clearence the slider instead of moving/clearencing the diff?

chris
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52 vwrx

[split_trix]

right got the input shaft installed now, just need to get the bellhosuing on over the shaft ?

chris
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52 vwrx

[doppelganger]