Here is my situation: 1984 300D. I am replacing axle shafts with new ones from China.

Without my axle spacers installed, I have somewhere around .5 mm too much play in the diff where the circlip goes. But I can get the circlip installed and it spins easily on the shaft. With the axle spacer installed, I cannot get the circlip installed. I don't think I can even get it to fit inside the groove at all, even before I try to lightly pound it into place. My spacer is about 1 mm thick.

I have searched in this site for a good while to find out what would go wrong if I have too much endplay, but I did not find anything.

What would go wrong if I have too much play inside my diff where the circlip holds the shaft in?

Will it end up breaking anything, like maybe the clip itself?

Would it cause the seals on the axle side of the diff to leak?

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1984 300D 398K-daily driver
1998 Honda Accord 102K -wife's daily driver
1991 Volvo 740 289K
2000 Toyota Corolla 143K

seem like there is a lot of issues with these chinese axles with quality control.

The spacers come in various sizes, can be abtained from the dealer.
this thread running now mentions it

www.peachparts.com/shopforum/showthread.php?t=266352


there was another thread running about a yr ago where the guy ground down the spacer. not sure how he did it though. It would have to be even and smooth not to cause any problems. hard to machine to a close tolerance with a grinder .

Charlie

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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

charlie, are you sure thats the right link?

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http://www.peachparts.com/shopforum/showthread.php?t=266352

this one maybe?

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?

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1983 123.133 California
- GreaseCar Veg System

You hit it on the nail.... That is all possible.

In addition, you might damage the spines from excessive side to side play.



.

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1983 123.133 California
- GreaseCar Veg System

Some aftermarket shafts are radius cut where the spacer rest. The rounded machined surface prevents the spacer from seating where it should.

In other words... China made axles are machined wrong.

I think I posted pictures of this a couple of years ago.

After reading about the "rounded machine surface" on the axle right where the spacer goes, I looked at my shaft closely, and mine were like that-they had the rounded surface. This made my spacer not fit flat against the axle shaft.

So I hand sanded the inside corner of both spacers to help them seat flat on the shaft. That worked-they seat flat on the shaft now.

I can now get the circlip on one of my shafts. But the other one still will not go on. It only needs a spacer about .3mm. Mine is about double that size.

I called the dealer and he says he can get the spacers. They start at .7mm thick and go up from there. He did not have any in stock, but checked and they were available at some of the MB warehouses. But .7mm will be to big too for my needs. I guess my only option is to have a machine shop grind down my spacer to the size I need.

Now I need to know the maximum allowable amount of end play. Anyone have that info?

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1984 300D 398K-daily driver
1998 Honda Accord 102K -wife's daily driver
1991 Volvo 740 289K
2000 Toyota Corolla 143K

My paper copy of the FSM ("Service Manual, Chassis and Body, Series 123, Volume 1" dated 1982) says (section 35-620, Removal and installation of rear axle shaft) "There should be no noticeable end play [my emphasis] . . . [h]owever, the locking ring should still permit turning in groove." Two pages later, "Check end play between inner spider and differential housing. There should be no noticeable end play; [again!] the locking ring should just barely turn in groove. If required, use thicker or thinner spacing ring."

The spec for end play is zero. What will happen if the axle has a little play I would not want to find out on my car but you go ahead, maybe it won't hurt (keep us informed). This is one of the risks of using non-OE parts. (I don't claim innocence either, I have off-brand stuff in my car.)

Jeremy

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"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

I'd rather use re-booted original axles than the China junk.

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-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 118k - mine - (OC-123,800)
'17 Metris(VITO!) - 37k - wifes (OC-41k)
'09 Sprinter 3500 Winnebago View - 62k (OC - 67k)
'13 ML350 Bluetec - 95k - dad's (OC-98k)
'01 SL500 - 103k(km) - dad's (OC-110,000km)
'16 E400 4matic Sedan - 148k - Brothers (OC-155k)

I repeat... "spacers are specific to axle/differential combination."

Every axle is machined slightly different which can be measured by looking at the distance from the clip groove to the shoulder where the spacer rest.

The FSM is vague about how tight they need to be but there does need to be some loading of the inner spider gear.
Also, you 'should' use new lock rings.

OOPS . I fixed it.

HMMM, maybe I need some of this stuff

Charlie

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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

Hey Cook, thanks for the info about rounding out the inside of the spacer to fit the axle as it should. I purchased FEQ brand axles and probably have this same problem. I had not looked at my axle machining that closely and will now. This may be just the trick for my problem.

I know others state not to use the China made crap, but am hoping they'll last the life of the car over here in Hawaii where I live. The cars usually rust away before the engines give out.

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85 300CD Turbo running straight vegi oil
97 Ford F250 7.3 Turbo running straight vegi oil

I had a garage install my CVJ axles 2 years ago. When I got the old axles back they still had the spacers on so I know they were never installed. Odometer doesn't work but I figure 10k miles on the spacerless axles. I guess I better have the diff oil changed and an inspection.

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1985 300D Turbo
"Evolution is God's way of giving upgrades" Francis Collins

I believe fruitcakesa used feeler gauges to decide what size spacer he needed. He has a thread on his struggle with the spacers.

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84 300D, 82 Volvo 244Gl Diesel