Editing Z31/vlsdInstall php (section)

=== The Process ===

Here’s a look at the types of retaining rings you’ll run into with BDO half shafts:

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/2.jpg

On the left is a stop ring (retains the inner race from sliding inward, best removed with stop ring pliers). The big ring in the middle retains the slide joint housing. The small middle ring is a compression ring (retains the stock Z31 turbo inner CV). The ring on the right is a snap ring (retains the Z31 turbo outer CV and the J30 inner CV from sliding off the half shaft; best removed with snap ring pliers).

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/3.jpg

'''Disassemble the diff side CV of the Z31 half shaft:''' BDO half shafts are simple. First remove the CV boot and clean off all the grease. The diff side CV is held on by a compression style ring. Knock the CV solidly on its inner race with a big hammer. This compresses the ring and allows the CV to slide off the shaft’s splines.

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/4.jpg

'''While you’re at it:''' Remove the wheel side CV for cleaning and greasing. In the end, you’ll need to turn the cage around to shorten the shaft—this is shown later.

'''J30 diff side:''' Remove the CV boot and clean the grease. Remove the big snap ring from the slide joint housing with a screwdriver, slide the slide joint housing off, and then remove the snap ring from the splined shaft with snap ring pliers. Slide the cage/ball/race assembly off. Remove the stop ring with the correct pliers.

'''Assembly:''' Slide the J30 diff side cage/ball/race assembly onto the diff side of the Z31 half shaft and reassemble everything. BUT WAIT! The outer snap ring groove will not be visible!

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/5.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/6.jpg

'''Solution:''' Mill new snap ring grooves into your Z31 half shaft (anyone with a 3 jaw lathe can do this). My neighbor helped. The stock shaft is on top; the newly milled shaft is on the bottom:

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/7.jpg

'''Once machining is done:''' Install the J30 boot, stop ring, cage, inner race, and snap ring onto your newly milled shaft (diff side).

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/8.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/9.jpg

'''Pack with grease:''' The Z31 housing (right) takes 4–6 oz; the J30 housing (left) takes 6–8 oz. A Dixie cup holds 5 oz. Test fit axles before filling with grease!

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/12.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/10.jpg

'''Assemble both CV joints onto the half shaft.''' (The pictures below show the cage in the OEM position.)

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/14.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/15.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/16.jpg

'''Install the half shafts into the rear subframe assembly.''' This may take a few tries to figure out what works. Besides turning the cages around, note the difference in companion flange lengths:

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/18.jpg

As you can see, 87–89 companion flanges are 10mm longer than 84–86 flanges. I used the 84–86 flanges for my setup to provide the needed room for the hybrid half shafts. Even with the extra 10mm, the shafts were a tight fit!

https://dev.z31library.com/xenonzcar_archive/z31/images/VLSDinstall/17.jpg