Lots of little stuff done in the last few days. Had a small leak at the line for the oil pressure sensor so I had to redo that. Changed the oil and added the temperature probe to the drain plug and ran the wires to the gauge inside.
Then I went to finish up this stupid rear diff. If I could do it all over again I would throw it in the trash and just spend the money on a new, modern, better rear LSD. I was trying to save money since I already had the early JDM R160 LSD sitting in storage with both special axles. That was a dumb move
The rear diff has been sitting assembled since Nov/Dec. I pulled the axles out recently to get them ready and when I unwrapped them (they were wrapped in shrink wrap) one has a ripped boot and and some spline damage.
I bought some aftermarket boot kits and after fighting with them for 45 minutes and being unhappy with the results I ordered the OEM ones from the dealer. Since I had them apart anyway and was waiting for the correct boots, I decided to refurbish them the best I could. I found the super hard to find dual spline DOJ on Amazon for $28 and installed that.
Then I checked the spline damage on the short side. It was pretty bad and wouldnt engage with the Diff. The splines at the tip were twisted and half missing.
Of course the internet is full of misinformation and there were a ton of old threads claiming the USDM 2.5rs axle fits in the short side so I went and bought one. Although very similar, the USDM axle has an extra bit of taper at the end of the shaft (the USDM diff is not tapered) to help engage the diff. Also the USDM axle doesnt have a very deep circlip groove because the clip stays in the diff.
The JDM axle has no extended tapered part to the shaft as the diff has the taper. Also the groove is deeper as the axle holds the circlip not the diff. The USDM axle fully engages until the opposites shaft is inserted, then it interferes. It also will obviously not stay in place without a proper circlip.
I could remove the damaged section of splines from the JDM axle and run only 2/3 the normal spline engagement or modilfy the USDM axle so I chose to modify the USDM axle. My cousin is a machinist for and OEM supplier so he helped me machine the axle to the correct dimesnsions to mimick the JDM one.
Before and after machining is below.
The worst part is, this is one that I bought back in the mid 2000ís from someone who said it was a ďmechanical LSDĒ Which everyone thought the same thing back then. I think it was proven to actually be an early Viscous unit. All this headache for a VLSD..... But at this point, itís all ready to go and Iím just going to install it and drive the crap out of the car. I can always swap in something better down the road. This was genuinely a bad decision trying and save a few bucks instead of just spending the money on a proper rear diff.