Need some info on VLSD output shafts

[Magoo1222]

1991 240sx hatch
Stock R200V VLSD, Stock axles, problem only became noticeable after installing 1 piece driveshaft and poly subframe bushings

I am trying to track down the source of a horrible clatter sound from my rear end whenever the wheels are turning. I have found a likely source being the passenger side output shaft of the diff (stock VLSD). I found the shaft has .5mm play in and out of the diff, which is being caused by a loose clearance with the locking c-clip. The driver side clip fits snugly on the shaft with zero play, thus zero shaft play in the diff.

I pulled the diff and replaced the bearing as a precaution (as the clatter was also accompanied by a howling bearing noise), as well as installed new c-clips from Nissan, however the issue of looseness still exists.

Can anyone confirm if the clip groove on my passenger axle is excessively worn, or if this play is normal? I have no way of comparing with a known-good output shaft in person or I would.

For reference, the clips measure at 2.44mm, the groove on the driver side shaft measures at 2.5mm (zero play), and the groove on the passenger side measures at 3mm and is also slightly chamfered on either side of the groove.

Driver side shaft, nice and tight, zero play, straight cut groove
http://i.imgur.com/YrU6S49.jpg?1

Pass side shaft, you can clearly see the loose clearance, chamfer, and inner wear where the clip has been moving around
http://i.imgur.com/nndNzIX.jpg?1
http://i.imgur.com/hAOooAg.jpg?1

[Magoo1222]

Bump, anyone have any ideas?

[zombiewolf513]

Just a thought, but how's the play in your pinion gear?

[Magoo1222]

Pinion is good, no excessive backlash, contact pattern with the ring gear is good. Its only the output shaft that has play, I checked with the diff cover off to make sure it wasnt a side gear moving around. The shaft has .5mm play in and out of the diff (the same as the difference between the clip and groove)

[KiLLeR2001]

The c-clip for the longer VLSD output shaft must be retained inside the differential itself. The shorter driver side shaft has the c-clip on the shaft itself.

What part number did you order? Almost looks like you ordered a driver side c-clip for the passenger side.

[Magoo1222]

The clips I got are #38225N3100, both clips that came out were the same size. Are the clips different from side to side? The driver side clip came out with the shaft, and the pass side stayed in the diff when disassembled

[KiLLeR2001]

Your groove on the passenger side shaft is normal. I have a few different sets and all of the grooves for the longer output shaft are wider than the driver side shaft.

All of the Nissan VLSD units I looked up include that clip with the differential unit itself so they aren't showing a specific part number. Only the driver side shorter shaft clip has a part number.

I did however find the clip with an infiniti OEM part #38225-32W00. I can't verify this will be any different in size as I have never ordered it, but its only $1.22 and worth a shot.

The part number you ordered is the clips from an S14 with open differential shafts.

[Magoo1222]

Well Courtesy Parts verifies the number fits an s13 VLSD, however it doesn't specify the quantity per car (of course), I imagine they made it generic for several models.

Curious, do you by chance know if Nissan used a paper gasket for the diff cover from factory, or RTV (like the oil pan)? Im almost wondering if someone had been into this diff before and made the same possible mistake (hence two of the same clip)

[KiLLeR2001]

Yes, Nissan uses paper gasket from factory. If you see RTV its been opened before.

edit:

Trying to go off memory but I believe the 0.5mm of play you are describing is also normal. I think your chatter may be something else, maybe a sound clip would help, lol.

[Magoo1222]

Ah, it had a paper gasket, that car was bone stock when I got it so I didnt really think it had been messed with before. I suppose for a few bucks I will try that Infiniti part. I appreciate it

[KiLLeR2001]

When you installed the 1-piece driveshaft did you remove the dust cover from the transmission? A lot of times this is overlooked and rubbing/noises occur.

And when installing the poly subframe bushings you retained the metal rings on the inside and didn't cut them out, correct?

[Magoo1222]

Yes, the dust cover was removed from the tail shaft on the trans, and the metal cups were left in the subframe (used Energy Suspension s14 poly bushings). Originally, there was a bit of noise/vibration with the 2 piece shaft, which I attributed to a bad carrier bearing. However, after switching to the 1 piece, the noise/vibration was still prevalent.

I crawled all over the car with a stethoscope front to back top to bottom while it was running in gear on stands trying to locate the source. The noise is much more noticable in higher gears at lower speeds