Easy 5-Lug Conversion - 911 Running Gear, For High Power Applications... Options

[Eric_Shea]

First, hats off to Paul (our previous cover-boy and Excellence darling) for turning the bulb on. We were chatting one day about CV's and such and he said something to the effect of; "just get the right length axles and be done with it."

Well duh.

Just get the right length axles and be done with it. No adapters. No extra bolts. No machining, no issues. Just get the right length axles and be done with it. It had a nice ring to it.

I was on a mission. The mission began with a post to get the proper 914 axle length - 20.25" (thanks Ron). Then the 911 spline count - 28. Then a call to Sway-a-Way... yup, part number 2420 in stock. MSRP - $305.00 Not bad, not bad at all for a pair of custom length axles. http://www.swayaway.com/OffRoadRacing.php

I want to make this harder than it is but honestly gang... it's that simple. Simply get the entire early 911 running gear and insert the proper length axle and you're done. Well, there are a few steps so let's see just what that gear is. From stem to stern it goes like this...

From a pre1974 911:

* 911 Rear Wheel Hub
* 911 Stub Axles
* Entire 911 Axle Assembly w/CV's
* 911 Tranny Flanges (901, 911 or early 915 transmissions)

I had the hubs, I grabbed the axles off a buy Reid made (Lavanaut, thanks!) and I picked up some flanges on eBay or PP (can't remember, getting old before your eyes). All I needed were those axles. All it took was money. While I waited for the axles I got started on the disassembly.

Dusty dirty axles... one of the messiest jobs:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232675907.jpg)

Using an air wrench... bolts coming out:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232675899.jpg)

Here's you'll see my method for stub axle removal. A BFH and a cold chisel. Be careful to position the cold chisel on the "gasket" between the CV and the stub axle to avoid cranking on the metal bits:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232675929.jpg)

They're here. Shiny new axles:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232675956.jpg)

The right length too. You can see the difference when compared to the 911 units:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232675941.jpg)

The threesome. Short = 911. The loaded shaft is a 914 shaft:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232675995.jpg)

I want to emphasize the difference because you simply can't run 911 axles in a 914 (for very long). People have bolted them up but, they hyper extend the CV's and they're gonners in a short while.

Remember all that dirty stuff in the first pics? Well, I make a weekly run to the platers so, my rewards are as follows:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676018.jpg)

(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676029.jpg)

(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676039.jpg)

Speaking of dirty stuff, the CV's needed to be totally disassembled and cleaned. To do this I stuck them in a gallon of that Gunk Carb Cleaner for a week. This is the best way to loosen hardened, caked on grease. When they came out it still took a couple rolls of shop towels to get them cleaned up. Once everything was cleaned it was assembly time. Not too tough really:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676161.jpg)

Start by fitting the inner race into the cage:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676177.jpg)

Then pop the balls in one by one:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676188.jpg)

Then drop the inner assembly into the CV. Simply match up the fat notch on the inside race with the skinny notch on the outside race to line up the path for the balls:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676221.jpg)

Then tilt it back and drop it in:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676247.jpg)

You may have to do a bit of rotating to make it easier but it's fairly straight forward:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676259.jpg)

Ready for the lube:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676320.jpg)

I start by putting the nozzle of the grease tube in the inner ball slots and filling away:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676342.jpg)

Inside started:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676427.jpg)

Then I do the outside the same way:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676380.jpg)

Flip them over and repeat. You do have latex gloves don't you? Once they are loaded you have to massage them by hand to work the grease throughout the joint. TAKE YOUR TIME and get the grease thoroughly into the CV. Notice the Moly-Lube? I use an entire tube for each CV. It's the good stuff.

Now the fun part... bolting it all back together. Here the CV's have new boots and freshly plated top plates:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676292.jpg)

Next the CV's get installed and clipped into place. Once the plates are in place it's time for new boot clips:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676443.jpg)

(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676459.jpg)

New bolts are made ready with new Schnorr washers:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676474.jpg)

...and a new CV gasket is mated to the CV awaiting the stub axle to be bolted on:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676506.jpg)

A quick referrence to the "good book" and let the torquing commence:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676864.jpg)

(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676520.jpg)

And we're done:
(IMG:http://www.914world.com/bbs2/uploads/post-1110-1232676926.jpg)

911 hubs go in the control arms. These shiny stub axles go into the hubs. The shiny nuts get torqued down and the other end gets a gasket and is bolted up to the transmission flanges.

Virtually bullet proof 911 CV's and a complete 5-lug conversion now reside under your 914.

[Harpo]

I will post over @ pelican and see what comes up

David