AE86 TRD LSD fit. Driveshafts wont go in! HELP

[tezza88]

Car: 1986 Kouki AE86
Problem: Rear LSD

Hey guys.
Got in abit of trouble with the 2way so hopefully im not the only one and someone has a neat trick behind it

Bought the TRD 2way year and a half ago (mabye from SamQ?) anyway got around to fitting it in last weekend and failed to finsih in 1 day

Heres my problem

Ive already gotten it into the housing, crown in, lined up, all good to go, but when i try to stick the drive shaft back into the new centre on the car.. it wont fit (had to take the shaft off the old one with a sliding hammer)

then took shafts out, tried to fit it with the diff outside the car, and its tight.. shafts proabbly bigger by less than 1mm..so needed some effort
Tried to push it into the old centre, same deal....so i guess hard to take out= harder to put back in

THEN
put it back together, sliding hammer back into the diff until about 2cm left to go in. and decided to massage it in with a bolt and screw to tighten it up and push in (thers a metal plate thats suppose to secure it all up- has 4 screw/bolt holes)
got to about 3-4mm left and it started to bend the plate so sliding hammer again, wont go the distance...

I'm sure its the right diff centre (kouki) so why isnt it clearing!?

Please no stupid comments, its taken long enough..i just want answers and skidmarks

Terry

[rthy]

part number of the lsd?

[sundee]

it should not be that hard ... the force needed to get the shaft to snap back into place is literally a few taps with a 20oz hammer, there is something wrong if you are needing all that force.

and the answer is you have the wrong center.

if the shaft is bigger by 1mm or so then you have a Kouki diff and you have fitter a Zenki Center..

more info here:

[sc86]

have you matched zenki shafts with zenki diff
kouki with kouki

sounds like you havnt

[blair]

I've had to use MASS Hammers before... but that was due to RUST! hahahahaha

(sorry for not contributing, but my comment would be the same as the above two guise)

[tezza88]

oh shit! it literally is about a 1mm difference between zenki and kouki...
is there any differences between the diff centre sizes? cause some people have told me u could tell by the housing measurements. and if thers a difference in housing sizes, then how would zenki centre fit into kouki housing?

thanks for contributing guys, its clearing up alot...now im wrorried i messed up the poor buggers

[tezza88]

OH! and would anyone in Sydney have an actual kouki 2way that i can compare with? just as reference between my trd one, original and your "real kouki" one

[Sam-Q]

no it's not my old center, I swapped mine with someone in Vic

[H8CHIR6KU]

you can tell if its the wrong axles.
one has triangle teeth with a sharper edge
and the other has a more squarish tooth with a flat edge

if their not the same then its the wrong centre

[Hen may possibly be a nut]

If you can get the axle in at all then you have the correct centre. They is no way in hell, no matter how big the hammer that you can get a kouki axle into a zenki diff. I couldn't get an E series axle into a kouki centre and they measure up the same diameter and spline count, the only difference is the spline shape.

I'd say pull it apart (again) and clean up the splines with some fine emery paper (especially if the centre has slight surface rust after sitting around for a while), oil them up and double check that the axle splines fit fully into the centre splines. Also clean out the bearing mount in the ehd of the diff housing and the bearing itself. If they are caked in crap it won't help with insertion.

And you may be experiencing a second problem in the last 20mm. Your axle coule be bottoming out in the centre. There's an old story that factory LSD axles are a few mm shorter than axles for open centres and open centre axles bttomed out when used with an LSD. Whether that is a problem with TRD centres or what you're experiencing at all I can't say but may be worth investigating.

Good luck
Hen