dc2 s80 box, different diameter shafts? one cv joint too big?


vag_to_jap

vag_to_jap

Member
Joined
Mar 21, 2014
Messages
61
Ok guys this is where I could use with someones help on this one!

So I've just bought my ek9 that has the 98 spec dc2 s80 gearbox, when buying it both cv joints needed replaced but two new cv joints came with the car.

Had my mate yesterday start to replace them, he replaced the drivers side with no problems then moved on to the passenger side and once attempting to fit the new cv joint onto the drive shaft noticed the the passenger side's half shaft is too small in diameter and doesnt grip the cv joint at all :((

Unfortunitly im not a mechanic but surely this means that the half shaft is thinner than the drivers side shaft as both the cv joints are identical and one fiited no problem meaning i've to different sized shafts!

How is this even possible? could the size change at the joint where the half shaft joins the other part of the shaft?

Apologies if i've made that sound confuisng, so if anyone has come across this issue or has any info please share as im lost on where to start!

Cheers.
 
Is it a problem where the driveshaft goes into the hub ?

98 spec tegs had larger hubs and I think the driveshafts are 32mm to match.
 
Its the drive shaft fitting the cv joint before it goes to the hub! The shaft is too thin and wont grip the cv joint.
 
'98 spec DC2's have a 36mm outer CV joint spline diameter (JDM & UKDM). Think they used the 36mm as the '98 DC2 was equipped with larger 16" wheels from factory.

'96 specs, EK's, EG's have 32mm.
 
So would the inside splines be the same size no matter if it was from a 98 dc2 or ek9 meaning its just the outside splines that change in diameter? Would that maybe mean someone has put a shaft, cv joint and hub from a dc2 and left a standard side of the ek9?
Thanks for the help.
 
Yes it's just the outer diameter which would be different at the CV joint, the gearbox fitment is the same across all B-series, either that or you were sold a D-series shaft? Don't know too much about them though.

Although gearbox could have been from a broken DC2 and they needed a shaft so used the hubs etc... from it as you have mentioned.
 
Thanks mate, I kind of thought the the box fitment would of been the same but like I say im no mechanic! just basically working on a process of elimination to find the problem.

I've one last question (for now lol) I've found that both hub nuts are 32mm which means both hubs are the same, right? so wouldn't it be possible to have two different sized cv joints but have the two same sized hubs?

Cheers.
 
UPDATE: got measuring the all round diameter of the drive shafts today and passenger side is 4mm thinner than the drivers side, shouldn't they be the same?

Passenger side drive shaft diameter: 80mm

Drivers side drive shaft diameter: 84mm
 
You must log in or register to reply here.
Back
Top