On the 93 open (non LSD) version of the MX5 diff, there are two splined shafts, with 4 bolts on them, which attach to the half shafts themselves. One is longer than the other. I have called around to local Mazda dealers in my area, called a transmission shop, to no avail. I can get one of these buggers into the diff by tapping with a rubber mallet as recommended, but the longer one WILL NOT GO IN!

I have emailed Flyin' Miata where I bought the diff and shafts in Colorado, USA, but I get no answer. I HAVE NOWHERE ELSE TO TURN! This "potential" car is driving me absolutely mental, with all the bolts needing replacing, and things not going on the way they're supposed to etc etc etc If I could drive it somewhere to be put together I would, but that is not an option. I'm going to go back on Diazapam at this rate (seriously).

[Edited on 20/9/07 by RK]

Hi RK

I have pulled appart my MX5 diff , and they knocked out and tapped back in , maybe check the clip around the start of the spline .
I can't think of any other reason why they won't go back in .

Good luck

Vaughan

Might want to post also onto mx5ocforum.co.uk pretty helpful guys. Or possibly give some other parts dealers a call and ask them 'if i bought part X, how would i go about fitting it?'

Sounds like a fairly common problem when putting inner CV joints into a diff --- as already mention the circlips sitting just a fraction too pround -- they need carefully squeezed in a a bit so they don't ride up and jam as the shaft enters the splines.

Problem solved. Thank you very much. By the way, on the 93, the longish one goes in the Right side when looking forward. It took a bit of "encouragement". OK, I bashed the hell out of it with wood and rubber!!!