HOW TO: Convert to real 5-lug in the rear using 944 CVs Options

[SirAndy]

Convert to real 5-lug using 944 CVs

This Article describes how to convert the rear axles on your 914 to give you real 5-lug hubs using a mix of 914, 944 and 911 components.

Tools and Supplies:

• BFH
• Two new 914 rear wheel bearings
• Four new 944 100mm 6-bolt CV joints including mounting bolts, boots and grease
• Two 911 ('75 - '79) 100mm 6-bolt coarse spline transmission output shafts
• Two output shaft seals
• Two 911 ('75 - '79) 100mm 6-bolt stub axles
• Four 911 100mm CV gaskets
• Two 911 ('69 - '73?) hubs, must have same bearing surface width as the 914 hubs
• Access to a lathe

Step 1: Preparing the axle shafts

Remove the CV joints from your old axles and machine both ends of your axle shafts to allow the wider 944 CVs to slide on.
You'll have to remove 4mm of material to make up for the wider 944 CVs.


4mm of material removed:


Stock 914 CV on the left and a 944 CV on the right




Step 2: Putting it all together

Grease up your new 944 CVs and slide them on the machined axle shaft *without* using the stock spring washer behind the CV!
Make sure the CV slides all the way on and don't forget to put the circlip back onto the shaft to prevent the CV from sliding off.
Note: Make sure the "groove" on the outside of the new CVs always points away from the axle (see picture with the complete axle).
Remove the old stub axles and hub. Remove the old wheel bearings. Install the new wheel bearing in your trailing arms.
Make sure the bearing surface on your new hubs is clean and press in the new hubs. Install the new stub axles and tighten the axle nut.
Remove the old output flanges from your transmission, replace the seals and slide in the new 911 flanges.
Grease up both, the output flange cup and the stub axle cup and install your new axles. Don't forget the CV seals!
Tighten everything to spec and enjoy!


911 coarse spline output shaft and 911 stub axle:


944 CV on 914 axle shaft:


Test fitting the output shaft on the 944 CV:


And at last, the completed axle. The top shows the original 914/4 axle, the bottom shows the new axle:


Mounted on the car:



Info compiled by SirAndy

[Aaron Cox]

Interesting...

I think you can run a 944 (non turbo/s/s2) automatic axle AS IS. I still plan to run the 944cv's on the 914/4 axles, but it looks like its possible to just buy what you need.

Top is a 914/4 axle, 33 splines.
Middle is a 944 Automatic Axle, 33 splines.
Bottom is a 944 Manual axle, 33 Splines.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.xx.fbcdn.net-219-1331959158.1.jpg)