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  #16  
Old 07-25-2008, 02:14 PM
fruitcakesa's Avatar
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Location: Vermont
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I phoned MB this AM and the parts guy had a list of spacers, none of which was even as thin as my original!
So I called my buddy Steve who is a jack of most trades including machine work and he said to bring the spacer over.
He put it on his surface grinder and shaved that sucker down from .034" to .026".
I rushed home and pulled the new axle that I had dejectedly left in the diff last night, slipped on the spacer put the axle back in and snapped in the circlip snugly. Yippee.
A word of warning however about aftermarket axles; the are just not made to the same spec as factory because in addition to the spacer issue, the new axle end bolts they supply were too long so I reused my original factory ones and torqued them to spec. I guess you really get what you pay for!
The RTV on the diff cover is curing so I will wait till tomorrow before refilling and taking it for a test drive.
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1981 240D 132k 4 spd manual http://www.fuelly.com/smallsig-us/40338.png
Finally got the clutch bled!
2004 VW Jetta TDI 5 speed 272k
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  #17  
Old 07-25-2008, 02:20 PM
Cervan's Avatar
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Join Date: Jan 2007
Location: olympia washington
Posts: 1,809
Quote:
Originally Posted by fruitcakesa View Post
I phoned MB this AM and the parts guy had a list of spacers, none of which was even as thin as my original!
So I called my buddy Steve who is a jack of most trades including machine work and he said to bring the spacer over.
He put it on his surface grinder and shaved that sucker down from .034" to .026".
I rushed home and pulled the new axle that I had dejectedly left in the diff last night, slipped on the spacer put the axle back in and snapped in the circlip snugly. Yippee.
A word of warning however about aftermarket axles; the are just not made to the same spec as factory because in addition to the spacer issue, the new axle end bolts they supply were too long so I reused my original factory ones and torqued them to spec. I guess you really get what you pay for!
The RTV on the diff cover is curing so I will wait till tomorrow before refilling and taking it for a test drive.
you only need to wait about half hour until you can fill it, dont drive off without filling it put your oil cap on the top of your car.
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Have you ever noticed that anybody driving slower than you is an idiot, and anyone going faster than you is a maniac?

As long as they would add one additional commandment for you to keep thy religion to thyself.
George Carlin (Wonder where he is now..)

1981 240d (engine donor 1983 240d) recently rebuilt engine hurray! - No more.. fought a tree and the tree won.

pearl black 1983 240d 4speed (Converted!@$$%) atleast the tranny was rebuilt.
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  #18  
Old 07-25-2008, 02:46 PM
Diesel911's Avatar
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Location: Long Beach,CA
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Quote:
Originally Posted by Cervan View Post
Cant you just use a large washer?
If the washer was not the thickness needed it would be the same problem.

In a Machine Shop when the surface grind something thin like the spacer they us an extremely strong Electrmagnetic Plate to hold it down.

I had something similar that I wanted to make thin and I Epoxied it to the Face Plate on my Lathe and took very light cuts on it until I removed the desired amount.
To get it off I heated the washer with a Propane torch until I could pry it off the Epoxy. I carefully scraped the rest off a the Epoxy of the Face Plate; which was made of harder material than the scraper.

Maybe to 2 hour trip to the Drealer is not looking so bad at this point. If you have a Vernier Caliper or Micrometer measure the plate you have. Figure out your best guess as to what thickness you think you need.
Call the Dealer and see what size spacers are available and the cost.
Maybe you can combine the trip to the dealer with anothe chore that needs to be done in town.
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  #19  
Old 07-25-2008, 04:19 PM
fruitcakesa's Avatar
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He had a magnetic surface plate and he ground the spacer from .034" to .026" Slick!
Maybe the next guy who needs a different spacer for his aftermarket axles will find it at MB but the thinnest one they had access to was 1MM or .039+" which was way too thick for me
And a word of warning about AM axles. You get what you pay for.
Not only did I have the spacer issue but the new axle end bolts were too long and I had to reuse my originals!
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1981 240D 132k 4 spd manual http://www.fuelly.com/smallsig-us/40338.png
Finally got the clutch bled!
2004 VW Jetta TDI 5 speed 272k
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  #20  
Old 07-25-2008, 09:18 PM
Diesel911's Avatar
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Sorry to hear that about the Axles. 3 members that I can remember have used the GSP axles with no problems that they spoke of.
This is a good thread about what to do when things do not go as planned.
I got new end bolts with my axles but reused the old ones anyway as I misplaced the thew ones; it has caused no problems for me.
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