HELP!! I am in the process of changing the passengers side half shaft. I had no problems getting the old one out but when trying to get the new one installed it will go in so far and stop. Within the differential I can touch the splined shaft but I need about 3/4 of a inch or so more.

Thinking that I somehow messed up something within the differential I was able, without much trouble, to reinstall the old one. I cleaned and re-lubed the splines on the new half shaft and tried again to install the new one but my results were the same.

Any help would be greatly appreciated.

Mark

Mark, sounds like this thread may be of service.

http://www.peachparts.com/shopforum/diesel-discussion/220000-w123-how-replacing-rear-axles-6.html

Most recent posts sound like a similar issue, but the DIY to start the thread is excellent.

Must be something in the air.

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On some nights I still believe that a car with the fuel gauge on empty can run about fifty more miles if you have the right music very loud on the radio. - HST

1983 300SD - 305000
1984 Toyota Landcruiser - 190000
1994 GMC Jimmy - 203000

https://media.giphy.com/media/X3nnss8PAj5aU/giphy.gif

What brand of axle shaft is the new one and where did you purchase it?

Some brands are better than others, and one area this shows up is in how well they fit. I don't have details about the different brands, but searching on the forum will turn up info about the brands and some of their issues.

I tried 3 different sets of inexpensive ones on my 84 300D, none of them fit right, some had loose bolts, etc.

By far the best thing I ever did was to get my money back for the inexpensive ones and send my old ones to be rebuilt. It cost a little more, but I got a great product, great boots, and the best part is that the old shafts fit perfectly!

Hope this helps some.

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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

These are GKN Drivetechs from Peach Parts. I did not know that the old ones could have been rebuilt. I wanted to avoid problems that is the reason that I opted for the GKN's.

Peach parts shafts should be good so ignore my previous info.

Give Phil a call at Peach to see if he has any suggestions.

3/4" is a lot to be off. Most confusing.

I would also closely compare the old one and the new and note any difference between them.

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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