A note for installing the axles back into the hubs. I could not get the axles to go all the way back into the hub. Tried pounding the axle from behind ( on the metal can). No luck. Bought an all thread rod (M8 1.25 X 3ft ) at the local bolt supplier with 2 nuts and a large washer, $5.75. Tried creating a slide hammer to get it to install, still would not go all the way in.
I finally inserted the all thread into the axle. Slid a plate over the rod and installed a washer and nut. Turned the nut with a box wrench and the axle slowly slid into position. Replaced the axle bolt, sleeve and a new washer and torqued to 30Nm as per the manual.


http://www.peachparts.com/shopforum/showthread.php?t=206875

Dave

__________________
1970 220D, owned 1980-1990
1980 240D, owned 1990-1992
1982 300TD, owned 1992-1993
1986 300SDL, owned 1993-2004
1999 E300, owned 1999-2003
1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD
1988 560SL, 100,000mi, owned since 1995
1965 Mustang Fastback Mileage Unknown(My sons)
1983 240D, 176,000mi (My daughers) owned since 2004
2007 Honda Accord EX-L I4 auto, the new daily driver
1985 300D 264,000mi Son's new daily driver.(sold)
2008 Hyundai Tiberon. Daughters new car

Thanks for the thread DMorrison. I looked all over the search functiona dn I could not find anything that detailed. I truly hope I do not have to go that deep into the hub but I just might.

I filed on the hub this morning after cleaning it very good with brake cleaner.

Do you all think there is a possibility that the axle from the Advanced Auto is machined incorrectly. I think the previous one I had was out of the same lot as the one I have now.

__________________
http://www.libertyagrifuels.com
1984 300D Turbo
1980 300SD Sold
1983 300TD Sold
Dagger 16 ft. Legend Canoe (for the weekends)
Marin Northside Trail Mtn. Bike

Are you sure you have the right kind of axles for the diff? IIRC there is about 4 different ones.

__________________
http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

There are many different ones. This is why the spacer shim from the right side may be a different thickness from the left.

Machining tolerance varies such that the length of the inner stub to the clip groove is different. The correct spacer (shim) sets this to the specific differential.

If you swap axles, chances are you will need different shims.

Still, this does not help solve zsmith29's problem of the outer splines not meshing.

It is possible the axle is not correct. Measure the diameter of the axle spline area to make sure it is the same. Also measure the spline size and gap as well as the total length of the axle part that goes into the wheel hub. If they are the same then by some alltread and install it the way I described above.
the post I linked you to is for replacing the bearings. Not the axle.
Her is the axle post.

http://www.peachparts.com/Wikka/W123RearAxles

Dave

__________________
1970 220D, owned 1980-1990
1980 240D, owned 1990-1992
1982 300TD, owned 1992-1993
1986 300SDL, owned 1993-2004
1999 E300, owned 1999-2003
1982 300TD, 213,880mi, owned since Nov 18, 1991- Aug 4, 2010 SOLD
1988 560SL, 100,000mi, owned since 1995
1965 Mustang Fastback Mileage Unknown(My sons)
1983 240D, 176,000mi (My daughers) owned since 2004
2007 Honda Accord EX-L I4 auto, the new daily driver
1985 300D 264,000mi Son's new daily driver.(sold)
2008 Hyundai Tiberon. Daughters new car

The one thing I know for sure is that the splines in the hubs are not faulty.
I think filing either is a bad idea, but if I was going to choose I'd go for the axle.
Personally, I'd look for an axle that fits. They're out there. I know because I did the job.

__________________
1982 300CD Petrol/Black Leather

I borrowed 2 axles that came off of an 83 240D and tried to put them in. Neither one of them worked.
They are going in about a 1/4 of the way and stopping, all 3.

What is going on here.

__________________
http://www.libertyagrifuels.com
1984 300D Turbo
1980 300SD Sold
1983 300TD Sold
Dagger 16 ft. Legend Canoe (for the weekends)
Marin Northside Trail Mtn. Bike

Have you tried to put the old one back in? Just to see if it will fit.

are these Homokenetic or Annular axles? Annular are the two piece and
maybe separate the two sections and see if it will fit into the hub. If it
will, then stuff it in and attach the other end in the Differential and then
bolt the two halves together.

hard to believe three of them won`t fit.

Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works