drive shaft options

[malncol]

I was making these posts as part of my project thread and not getting much response so it was suggested to start new thread. Ive copied the posts over to here.What iam trying to do is to come up with a shaft which is readlly avaiable here in OZ that suits S2/S1E2. what seems like common knowledge too you guys isnt to me as ive never even seen a S2 here in OZ ,so i need the basics in some cases.
These are the copied posts


so in regards to the drive shafts , ive measured the short shaft at compressed lenght of 578mm app
so my question is if i add a spacer of 15mm it should then fit in the other side??
so it appears that the S2 short shaft in unique to S2 ??
has anyone found a of the shaft audi/vw/merc shaft thats close enough to fit , i would like to fit same shaft to all corners
iam sure someone has been here before
any ideas
thanks
mal

[malncol]

copied post
i thought i read the rears are same as fronts just on opposite sides? but this is not correct.
how are they putting front shafts in the rear when the LHR shaft is shorter than the short front shaft, if that makes sence?
wouldnt the shaft bottom out??
this is making my head hurt ,going for burbon now
thanks
mal

copied post
ok the short rear shaft measures 565mm or 22 1/4 inches long
closest ive found is
1998-2004 A6 quattro LHF A/T which measures 22 inches long

so we use it and place spacers to suit and fit to all 4 corners??
thanks
mal

only thing i cant find is if it has 108mm inner??

[malncol]

copied post
ok iam sure someone will tell me where ive gone wrong??
A6 LHF shaft is 565mm which is same as LHR S2

565mm + 0 = LHR
565mm + 15mm = RHF
565mm + 25mm = LHF
565mm + 35mm = RHR
the outer joint appears to be the same as S2 , but the inner is not the same style joint but i think it would work??
would it be strong enough??
also planning on fitting A6 front hubs on all corners as ive got to make caliper brackets etc so will make to suit A6 offset??
thanks
mal
copied post
receieved the new A6 shaft and the outer is a matter of removing the ABS ring and i will have to bore the hub out were the ABS ring would sit as the new shaft is 77mm under the ring and the housing is 75mm The outer spline is a match A6/S2 but iam running A6 hubs so doesnt matter to me.
The inner joint maybe more of a problem ,its way bigger than the 108mm S2 flange but as i will need to make spacers i can adapt from the 108mm S2 to the A6. This will be a prob for the LHR as there was to be no spacer on that corner?

So some questions for some options
will any of the A6 gearbox output flanges go into a O1E box?
has anyone got any ideas on the rear problem??
thanks
mal

[malncol]

copied post
i think i need output flange to suit O1E but needs to have the 130mm bolt pattern??
help
thanks
mal

copied post
ok so ive pulled the output shafts out of a B4 that i had laying around and it has the 130mm flange to suit the shafts i want to use but they are to big were the shaft support/bearing runs?? easy fix turn down to same dia as the S2? next problem is the B4 has circlip end, S2 has bolt through shaft .
qeustion
circlip would be stronger but how strong are the S2 outputs with the bolt?
if i go circlip i need to change the diff centre to suit which is a lot of work and as ive already fitted wavetrac diff might not be worth the trouble
so i can bore the B4 shaft to use the bolt from S2 or as i asked early is there a output flange from other model which would work???
dont seem to be getting any coments one way or another , iam i going about this all wrong, is there a better option?
thanks
mal

[caterpillar]

the propshafts are 3 parts unit, so you may buildt your one verson, the inner , the senter, and the outer unit...the spline and the lengths are different, and the hubs on the 01e are interechangable with other trannys, and diffs.. why the audi/ vw does so many versons of the same thema, i will not understand that..

[malncol]

question ,how strong are the output flanges for the box and the diff with the bolt through the middle??? circlip option is looking like a lot of work for some gain
also what is the weakest point in the S2 driveline??
thanks
mal

[caterpillar]

the weakest point are the spline anyway...it very many of the spline... 4places in one propshaft...

[malncol]

so the shaft and joints would be ok , it would be the splines in gearbox and hub because the have the hole through.Thats why i wanted to go to circlip output shaft
thanks
mal

[Error404]

Usually its the shaft at the spline or CV at the spline that breaks from what I have seen. Never seen a broken drive flange on a gearbox

[caterpillar]

i will use the biggest flange it the diff and tranny (115 or so from audi s6 or likly) and the biggest cv from other audi /vw ( eurovan)... not som custom/ spec made parts... remember i do have the 32b....vw chassi, with audi everything....

[malncol]

i will use the biggest flange it the diff and tranny (115 or so from audi s6 or likly) and the biggest cv from other audi /vw ( eurovan)... not som custom/ spec made parts... remember i do have the 32b....vw chassi, with audi everything....

if your still using O1E box then the spline size and the bolt holding shaft into gearbox/diff wont change ? best i was hoping for was to make them circlip so the shaft was solid/stronger.
the worst spot to have a break is spline inside box/diff so if they break at wheel end its not so bad
thanks
mal