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Old 01-03-2014, 08:08 PM   #1
TXwrxWagon
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WRB not so minty fresh

Default Drivers axle keeps popping out what should I order.

Ok, '04 wrx wagon. With Cusco adjustable rear lateral links, trailing arms. STI rear sway bar, kart boy end links and SEDAN axles.

Haven't had an issue until about 3 weeks ago & now drivers axle has popped out 3 times , & of course at the worst times.

Can I just order the cir-clip and reinstall or do I need to find a complete rear did with unknown cir-clip age?

Can I install the replacement clip without breaking down the dif from the car and totally disassembling the diff itself? What is the proceedure?

I have read enough to know I won't get the axle back in with the clip on the axle. So I just want an idea of what I am up against.

Thanks

Rob
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Old 01-03-2014, 08:11 PM   #2
TXwrxWagon
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That should read "without replacing the entire rear diff"

Rob
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Old 01-04-2014, 09:32 AM   #3
mhoerath
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The circlip on the axle at the diff end? That is designed to tell you when the axle is seated, not to hold the axle in place.

The axle is held in place by a number of nuts and bolts. First the axle nut on the knuckle end. The axle nut is bolted against the knuckle. This nut must be torqued properly or you will have wheel bearing problems.

The knuckle is held in place by the strut (top) and lateral links (bottom), held in place against side to side forces. The lateral links are connected to the knuckle with the long bolt. The trailing arm holds the knuckle against forward and backward forces.

All correctly torqued? What happens if you push and pull the tire with the tire off the ground? Any movement, sounds?
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Old 01-04-2014, 06:25 PM   #4
TXwrxWagon
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WRB not so minty fresh

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interesting... All the link arms and axle nut and strut are. But Since my arms are adjustable I am going to check if the jam nuts have backed off and if the arms have shifted. I didn't think of that... THANKS! easy fix, even in a hotel parking lot.

Will check tonight after work.

Rob
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Old 01-05-2014, 08:44 AM   #5
mhoerath
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Quote:
Originally Posted by TXwrxWagon View Post
interesting... All the link arms and axle nut and strut are. But Since my arms are adjustable I am going to check if the jam nuts have backed off and if the arms have shifted. I didn't think of that... THANKS! easy fix, even in a hotel parking lot.

Will check tonight after work.

Rob
ja mon, that could be the culprit. Also check your lateral link bushings.
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Old 01-05-2014, 09:49 PM   #6
TXwrxWagon
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WRB not so minty fresh

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the links are all heim/spherical rod ends. and are less than 20K miles. :-)

Temps here dropped like a rock, haven't had a chance to look yet. Gotta do it tomorrow. Gotta drive from dallas to houston for work. gotta figure this out ASAP.

Rob
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Old 01-06-2014, 09:36 PM   #7
TXwrxWagon
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Well everything inspect
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Old 01-06-2014, 10:14 PM   #8
TXwrxWagon
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WRB not so minty fresh

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Everything inspected and all is tight and to torque spec. Shaft pulled out nearly 3/4" this time. So called oreilly and have an axle being delivered to the closest store. This time it pulled out between 3/4"-1" as opposed to the previous 1/4". Axle comes with new nut. I measured all 4 lateral arms and all are correct and tight.

I am leaning toward a too tightly packed CV joint not giving more than anything, the axle does not flex, even when dislocated AT ALL... No articulation at all. I just replaced both rear axles about 3 months ago but haven't been driving it because I have been on the road for work.

The passenger rear side is much looser. So I think it's just an over zealous CV rebuild/repack.

We shall see tomorrow. The weird thing is I put everything together on last Monday and drove nearly 100 miles without an incident. Got up Tuesday morning to go to work, axle popped pulling out of an easy hotel parking lot.. Makes no sense.

Will update tomorrow afternoon.

Rob
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Old 01-07-2014, 04:49 PM   #9
mhoerath
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Interesting. The inner cv (as I extend my fingers from memory) has maybe 2-3" of travel. The green can has slots along which rings travel, with the can on one side and the rings attached to the other side of the axle.

With axle out mine had very easy travel. And travel they must as the outer end of the axle goes up and down with the knuckle. If yours does not travel something is jammed keeping the rings from going back and forth in the slots. Extra grease will simply flow into the CV boot, doubt that's the culprit.

If you want you can disassemble and inspect. Expand the outer and inner boot bands, you might be able to re-use. Pull the boot away from the joint. Feel for the wire clip holding the 3 sided lobe/rings, it's at the very end of the green can. One end is open. Pull it out.

Mark the location of lobe 1 to slot 1. Gently pull the lobe out. Note the location of ring 1, 2 & 3. to lobe 1, 2 & 3. Clean all grease out - have lots of paper towels. Brake cleaner helps. The slots should be smooth. The rings should be round.

Re-assemble same rings to same lobes, and same lobe to same slot. Use lots of spec grease. Re-apply clip, and seal both ends of cv boot.

You say replaced your axle(s)? Problems start with that?
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Old 01-07-2014, 05:28 PM   #10
TXwrxWagon
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2004 WRX Wagon
WRB not so minty fresh

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We'll more digging today. The reason for no movement when semi-installed is it was jammed. Picked up new (warranty replacement) axle and blew it all apart this afternoon. Axle is actually reached on the inside cv. I mean you hold the axle straight and the inner cv flops loosely to hanging toward the ground. It's failed completely.

No biggie have a fresh new axle. Put it all back together. Discover that the issue is indeed the inner cir-clip. It is worn/broken/whatever. The axle pushes in fine with a solid thud. But drive it literally straight from one parking spot to the next row in the hotel parking lot the axle pops out.

Yes both axles were replaced/swapped for new sedan axles to match the sedan style cusco rear links/arms less than 6 months ago with no issues until 3-4 weeks ago. When I am guessing the cir-clip gave up the ghost. Ruining the driver's inner cv.

So I have cir-clips coming from Subaru overnight for tomorrow. Now I need to figure out how the cir clips a install. I hope from the axle bore... I don't want to disassemble the diff carrier f I can avoid it.

I'm almost 2 hours from home working in a hotel parking lot. My wife is driving over tomorrow to bring tools, parts and support...

I'm going to call Cobb tuning in Plano, TX to see if a guy I know there can tell me how the cir-clips install.

Rob
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Old 01-07-2014, 09:01 PM   #11
tibug
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Default woops

woops...
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Old 01-10-2014, 01:21 AM   #12
TXwrxWagon
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Join Date: Oct 2008
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Vehicle:
2004 WRX Wagon
WRB not so minty fresh

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makes you feel really great when 15-20 year subaru, veteran tech's tell you they have never had a cir-clip fail... maybe I just need to swap the diff and be done?

Rob
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