Let me start this thread by saying that I was not looking to solve a mystery or bust a myth when I started this procedure. I just wanted to rebuild my tired old 76 280Z half-shafts!

I think there was a very common myth that the S30 half-shafts were different sizes. The driver side being shorter than the passenger side. Even though the distance from the wheel hub to the differential differs (more-so with the R200) from side to side, the half-shafts are IDENTICAL! The amazing amount of lateral play in the shaft allows it to expand or contract almost three inches. ...on to the pics!

First a shot of the shafts after I ran one through the media cabinet next to the other.

The removal of the u-joints is straight forward, several well documented methods on line if you need help there.

Now the science! Here you can see that the axles are identical in each dimension. Also note the layout of the snap rings, retaining rings and the balls and spacers.

And for those that were still disbelieving, a shot of a 240 half-shaft next to the 280 half-shaft. 240 shaft with the u-joint still attached.

Then on to refurbishing! You will need 4 new u-joints. SKF UJ393, MOOG 393, or Precision 393 will all work or any variation thereof. I media blasted the shafts and protected the bearing surfaces while doing so. I then painted the exposed parts in Cast Iron engine paint from Duplicolor. Love the look! I re-used the old boots as they were in great shape.

After blasting the shafts and painting them, I turned the boots inside out and fed the wide side over the bearing shaft. I used the cut-off top of a funnel to aid the narrow end going over the shaft and up into position. Worked excellent. Leave the boot inside out for now.

Slide the upper retaining ring and snap ring on to hold the shafts together, tuck them up by the boot. Refer to the above pic for proper order.

Attach the lower retaining ring and snap ring. Put the cleaned spacers and bearings into a zip lock bag full of a good quality bearing grease and ensure they are coated nicely all around. Place them in the channels in the correct order, ball bearing at the bottom, spacer at the top. The grease will keep them in place. Add about 10g of grease to the top of each channel.

Carefully slide the shaft back into the axle while ensuring the ball bearing and spacers are supported by the retaining tabs. Make sure the shaft is orientated correctly, the same direction as the axle end! Try and keep the bearings at the bottom of the assembly as it goes together. Holding it vertical helps.

When the shaft is in the axle, add another 30g of grease to the top of the shaft, concentrating on the open groves of the axle that did not receive the bearings. Use the retaining ring to push it all together and seat the bearings. I used a screwdriver and hammer to tap the retaining ring flat. Worked great, didn't need much pressure.

Reattach the snap ring to the axle at the top. Wipe up the grease you got everywhere... and pull the boot back down outside-in , ensuring the top fully inverts and seats in the groove, same as the bottom. Attach your favourite brand of cv boot clamp over the boot ends and securely tightly. Mine had not arrived in time for the pictures.

Proceed on to installing the u-joints, being careful not to damage the pretty paint! Grease the u-joints and you are done! Another 40 years of glorious torque!

 

 Thanks to Jim @zKars for his guidance and wisdom.

Edited February 5, 20196 yr by wheee!
typos, clarity

Great work. Thanks for sharing!

And just before someone else posts it  >>>  https://www.youtube.com/watch?v=i2nuPVTU4Z4

Boot Trick

 

 

Edited February 5, 20196 yr by 240260280

That is a great trick! I didn't think of that. I saw many videos on pulling the boot over the entire knuckle with a cone, but didn't want to damage the "unobtanium" boots that were in pristine shape. By turning them inside out, it also lets you clean out all the old grease easily. I will try and get a pic of the cut off portion of the funnel I used. Worked super well.

Don't forget to clamp the boots ?

I mentioned that the boot clamps had not arrived yet in the original post... but having said that, I found the original style of boot clamps and the proper tool for installing them on eBay for about $25. I will post pics of the boot clamp install when they arrive.

Are the boots unavailable?

20 minutes ago, Patcon said:

Are the boots unavailable?

No, they are available. But to Canadians, they are almost unobtainable for a reasonable cost. Some suppliers list them, even at a reasonable cost (under $20 each US) but then they want up to $90 US to ship them!!! Canadian suppliers claim no stock and no one can seem to order them. Part number EMPI 86-1164-D is the replacement part. If anyone can order them down south and ship them up... I'm in for a couple! 

Various Z car suppliers have them too, but with small orders like this, it is prohibitively expensive to ship. Most want to use Fed Ex or UPS instead of USPS. When those packages hit the border, they get hit with brokerage and duty and taxes. Duty and taxes I have no issue with, it's the brokerage and document fees that are stupid. I had a $20 item ship to me from the states via UPS and arrive with $64 in fees attached...

Edited February 5, 20196 yr by wheee!

3 minutes ago, wheee! said:

No, they are available. But to Canadians, they are almost unobtainable for a reasonable cost. Some suppliers list them, even at a reasonable cost (under $20 each US) but then they want up to $90 US to ship them!!! Canadian suppliers claim no stock and no one can seem to order them. Part number EMPI 86-1164-D is the replacement part. If anyone can order them down south and ship them up... I'm in for a couple! 

My condolences.

PM me and we can see if I can help

Mark and I have communicated and will hold off for now.

However I did some looking and it appears Courtesy can get the older boots up to 11/76. I don't know what the difference would be. the later boot shows as NA

Grease used back in the day contains lead. Take the necessary precautions or don't.

Gloves and mask, pretty much all the time in the shop!