C35 Gearbox Output Shaft Housing

[desmodave]

86HCI with C35 gearbox: Is it possible to remove the output shaft housing with axle intact with trans in the car, or does the assembly need to be removed per the shop manual? Axle seals are fine but the gasket between the output shaft housing and gearbox is leaking and needs R & R'd.

Thanks,
David Reese

[Esprit2]

[quote] 86HCI with C35 gearbox: Is it possible to remove the output shaft housing with axle intact with trans in the car, or does the assembly need to be removed per the shop manual? [/quote]


Yes, but you have to do a little digging to get to it.

Unbolt and drop the inner end of the halfshaft. Remove the brake caliper & disc. Hang the caliper from a wire or something... don't let it dangle from the hose. Remove the tranny/caliper bracket. Basically strip the output shaft housing naked. Then remove the bolts that hold the housing to the gearbox, pry to break the sealant, and pull it off.

The inner end of the output shaft is splined and will pull right out of the differential. There are bearing spacers just inboard of the housing that may fall out when the housing is removed. Watch for them and don't let them fall.

Clean a mating surfaces thoroughly. The manual says use a silicone sealant. I've had better result with Loctite 518 ( or the Permatex version... Permatex Anaerobic Gasket Maker, model number 51813). It's similar to Permabond A136. Apply to both metal mating surfaces, place the gasket and re-assemble.

Apply a medium strength thread locker ( Blue Loctite 242 / 243 or Avdelbond A138) to the bolts and torque them to:
7mm = 20.3 Lb-ft / 2.8 Kg-m / 27.5 N-m
9mm = 28.9 Lb-ft / 4.0 Kg-m / 39.2 N-m

Careful... the small, 7mm thread is easy to strip out in aluminum. Use a proper small torque wrench or a bending beam wrench. Don't trust a large clicker torque wrench. If it's a little out of adjustment at the low end, you'll strip the threads and never even feel it with a long handle.