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Gear box and Shaft will not locate.
Posted: Sun Dec 14, 2008 8:49 pm
by BlackMale
Its an L series AWD box and I can not get the dam drive shaft (or what ever you want to call it) to locate in the back of the gear box. It will go in about the distance to where the teeth/groves start on the shaft and then will travel no further. I have attempted to lube/move/adjust just a few mil and attempt to insert again however it will not go all the way on.
In addition to his i have inspected the rubber seal and shaft (from what i could see) on the gear box and the teeth on the shaft itself - all appear to be ok. I have 2 other shafts here and all 3 look exactly the same (with 1 tooth/grove missing opp each other).
I do not have a spare box here anymore to compare the differences. I have even taken the shaft apart at the centre bearing and attempted to tap it in with the rubber mallet however nup, no success. Any ideas? (its doing my freaken head in).
Cheers.
Posted: Sun Dec 14, 2008 9:04 pm
by Matatak
well first of all is it the right spline?
try putting it in gear and try. assuming its mated to the engine then it cant turn the output shaft (off the box) with the Tailshaft as your trying to insert it if the splines are not aligned yet.
What do you mean by "With one tooth/groove missing opposite each other"?
Posted: Sun Dec 14, 2008 9:10 pm
by Alex
loosen off the pressure plate bolts and the box should slide on. Then tighten them thru the starter motor hole. You'll have to turn the motor over via the crank pulley to access all the bolts to do them up again
Alex
Posted: Sun Dec 14, 2008 9:22 pm
by AndrewT
Guys, he is talking about inserting the tailshaft into the rear of the gearbox...
Craig just persevere, sometimes they can be a bastard. Insert it to the point where it stops then take the pressure off slightly and just rotate the tailshaft gently, soon enough you will find the spot and it will just drop in.
As far as I know there are no differences between models here, I have never heard of different L series tailshafts depending on model (except auto ones which are a different length).
Posted: Sun Dec 14, 2008 9:27 pm
by BlackMale
Yer thanks Matatak i did mean to put it in gear and kept forgetting – I’ll try that next time I am out there.
Alex I am not sure how this would help, I think you’ve got the wrong end of the box. If not you’ll need to clarify this for me.
Matatak wrote:What do you mean by "With one tooth/groove missing opposite each other"?
When i had a look all 3 L shafts had an entire tooth missing 180 degrees apart from each other. All 3 are genuine Subaru L tail shafts (thanks do you think I could think of that 10 minutes ago) and all look the same so I just figured that’s how they are – I have to say I have never looked before as the little buggers have always just gone on. The box does not have the same tooth missing however 1 of the shafts came off this box so any one of them will/should fit back on (i would have thought).
Maybe i just need to stop being soft with it.
Posted: Sun Dec 14, 2008 10:38 pm
by Alex
BlackMale wrote:
Alex I am not sure how this would help, I think you’ve got the wrong end of the box. If not you’ll need to clarify this for me.
lol whhoops....damn lack of sleep.
lots of WD40 has helped me slide the tailshaft onto the back of the box. Thats all i can say at the moment.,
alex
Posted: Mon Dec 15, 2008 10:19 am
by BlackMale
Dam there a huge delay in the posting time here - AndrewT your post was not there last night!?
Thanks Andrew, its just peeved me off and i though that maybe i missed something.
No worries Alex.
Posted: Mon Dec 15, 2008 10:30 am
by AndrewT
Yeah you might have just not noticed it, I posted it while you were already in the process of replying (I know this from looking at your "current activity" at the time) so it ended up positioned above yours. Good luck with getting it to fit!
Posted: Mon Dec 22, 2008 7:10 pm
by BlackMale
OK there will almost need to be a reward for whoever can solve this 1...
Basically i spend 1/2 an hour stuffing around with the shaft and it WOULD NOT locate on the back of the box... box in/out gear, mallet no mallet, greese, Lanolin all = sweet F/A.
P1ssed off and fed up i went back to the shed for another tail shaft to compair in the bright day light. They still look EXACTLY the same however heres the kicker... 1 shaft fits perfectly (slid on with box out of gear just as it bloody should) with no effort at all while the other 1 will not fit regradless.
Pictured below is 2 L series tail shafts. Note both shafts are from manual L series's. If you want more detailed pictures let me know however someone want to have a guess at what i have missed and why 1 of the shafts will not fit... its got be buggered?! I should add that i have measured the 2 shafts and there is less then 1mm difference between the 2 shafts.
Not a bit issues if noone know's as at least i have a shaft that fit.
Cheers.
Posted: Mon Dec 22, 2008 7:47 pm
by AndrewT
I'm interested to come over and *feel* the problem for myself!
Try dusting some talcum powder (or similar) on it, test fit, take it off and see if there are any obvious marks where something is scraping or something. Maybe the shroud which your fingers are inside in those photos is slightly mis-shaped.
Posted: Mon Dec 22, 2008 8:17 pm
by stamp_licker
Maybe a burred spline in the shaft or evena wee bit of rust.If its got grease on the inside is it hydraulicing[bad spelling].Even liberty t/shafts will fit onto a l box.
Posted: Tue Dec 23, 2008 5:11 pm
by BlackMale
Nup i have had my fingers all over both splines (fe/male - up to the knuckle) and nothing obvious no cuts to finger did not feel anything ect.
Yer i did think about corrosion so i gave it a very light rub'n with the file and then some lube but nope.
I did think about the grease option and wiped it all out and then soaked in Lanolin, still nothing.
See this is why i was getting peeved off. I do like the powder idea Andrew but not sure if i can be bugged cleaning/degrease off all the lube only to dry and cover in powder to see if i can where its hitting. Maybe if i did not have a shaft that fit

If i ever get it sussed i'll be sure to let you know but.
Posted: Tue Dec 23, 2008 6:36 pm
by bluesteel
could try counting the number of splines on the box, and on the tailshaft
may just be some strange freak shaft :P
otherwise try a big hammer and just belt it on (a spare box would be good for that tho) youll soon find out if its going to fit or not
Posted: Tue Dec 23, 2008 6:44 pm
by Outback bloke
Did the one on the right go in and the one on the left not? Top pic I am talking about.
Posted: Wed Dec 24, 2008 10:04 am
by BlackMale
Outback bloke wrote:Did the one on the right go in and the one on the left not? Top pic I am talking about.
Hmmm, you'd be correct - care to elaborate or you just taking a punt?
Posted: Wed Dec 24, 2008 12:49 pm
by Outback bloke
The one on the left looks like it has surface rust as already said. If they have any rust they won't go in. You need some fine wet and dry and to give it a really good clean.
Posted: Wed Dec 24, 2008 9:09 pm
by AndrewT
I figured the freshly painted one would be the one first intended to be installed?
Posted: Sat Dec 27, 2008 3:12 pm
by Lang
Is it my eyes or the photo however the right hand side shaft appears to be slightly oval.
Posted: Tue Mar 17, 2009 9:51 am
by AndrewT
Did you end up resolving this?
Posted: Tue Mar 17, 2009 7:35 pm
by Subafury
long time between posts so i hope so. usually they are piss easy to slide on.