Rear Shaft Movement

[cazman]

I hope this video link works.

I rebuilt my rear suspension last fall, including all bushings, new u-joints, axle rebuild (with new bearings, spacers, and locktite 635?) and I still had play in the assembly. I drove fine. It seems like the play is in the output shaft of the trans. The shims and roll pin are done correctly (spent too much time on that part). It is not clear to me from the manual if this is ok or not. Is this normal?

https://drive.google.com/file/d/1EaBFEAZjsZ4kVqZGZhfKwKdH8FawaP8f/view?usp=share_link

[GavinT]

It looks to me that the gearbox output shaft needs shimming . . and by more than a smidge.
When done correctly, the shaft should have no real axial movement. Perhaps the spacer became hung up on the O-ring?

I'd suggest punching the pin out and doing it again.

[cazman]

It's the same on both sides. If I shim the smallest amount (I took a shim and sanded in thinner), it will not let the pin through. I cannot get it any tighter. I guess you are saying that this is not normal.

[jbcollier]

Absolutely not normal, sorry.

Have the pins sheared?  Are the shims still tight?

Otherwise it is internal.

[cazman]

It did it after the suspension rebuild. It was probably there before too.  New pins, tight shims. I think I will measure the pin hole in the output shaft and see if that is enlarged. I suspect not.

I'll see if I can move the output shaft in and out without the drive shaft connected. That should verify slack in the trans.

[TurboFource]

I just did this today and found if I used a ratcheting strap to make sure the u-joint flange was all the way in, I got I different result than I previously did. So I reshimmed them and installed the spirolx pin with the strap in place. The spirolox (spring pin) is also thicker in one direction because of the way they are wound. I put this thickest dimension in line with the axle so I had the maximum thickness (diameter) holding the flange against the shims etc.

[cazman]

That is interesting. I do not understand what you meant here. "I put this thickest dimension in line with the axle so I had the maximum thickness (diameter) holding the flange against the shims etc."

Do you mean rotating the Spirolox in the hole?

[TurboFource]

Yes ( I may be calling it the wrong thing)

[jbcollier]

If the pin is in place, not broken, then the tranny has to come out and the diff spider and side gears shimmed up or replaced.  There should be virtually no in/out movement of the output shafts.  Your video clearly shows a lot of movement.

Why does this happen?  Incorrect shimming.  If not shimmed correctly, the suspension loads are not taken by the huge diff carrier bearings but by the side and spider gears inside the diff.  They do not last long under these conditions.

[cazman]

Ok, I checked it out. I still think that shims and pins are in correctly. However, I did that not too many miles ago and then noticed the play after. Who knows how long something was wrong before that. One pin was cracked back then too.

With the shaft off, I have .015 play in/out on the output shaft. I guess that's it.

Now, how hard is this to fix? Can it be done by a DIYer?

[jbcollier]

Absolutely.  You have to disassemble the transaxle though.  The Lotus manual is crap.  Get a factory Renault manual as it much clearer and easier to follow.  You'll need to borrow or make a special tool or two.  Where are you located again?

[jbcollier]

NY, I see.  You have a TC/S, 4 or 5 speed?  Which one? (336, 352, 365, 395, NG3)

[cazman]

TCS, 365 5 speed.

[jbcollier]

Tools you will need over and above workshop tools:

- dial gauge for setting backlash

Harbor Freight or similar will have something inexpensive and useable.

- open ended wrench for the speedo drive gear

I filed a bicycle headset wrench to suit and then welded a cheap socket to it.

- output shaft seal holder tool

You can use a 4WD bearing tool (can't remember the number) or I can loan you the correct tool.

Hard/impossible to find parts for a 365

- ring gear and pinion shaft

- anything to do with 5th gear

[TurboFource]

I used Performance Tool W1270 Ford/GM 4 wheel drive lock nut tool...on Amazon etc.