Desperate Need Of Kouki Axles

[Hen]

I know it is wierd, the axle spline measurements are both the same (axle diameter and spline count) but the spline shape is slightly different and just doesn't fit. It had me puzzled and got me wondering whether there are different E series splines.

I pulled 3 axles from 3 different E series plated YR20/21 Taragos and none of them fitted.

Hen

[GA61XX]

The axle's i have are, Not from, a Tarago...!!

Q:- But what is the spline shape..??

[styler]

read thread + got new kouki lsd + e series tarago axles = no go.
fark.

at least i prepared for it not fitting and have an alternative plan.

yeah i wonder if there are other versions of e series splines?
doesnt seem likely but it would be a godsend if true.

[AZA510]

what i did was looked on www.club4ag.com in the reference section where is talks about the different axle sizes. in that article is has 2 photos, they are of a guy holding a set or verniers measuring the 2 different axles. if you look hard enough you can see the measurement. so I took my set of verniers to a wrecker and pulled axles out of Toyotas for a few hours until I found one the same as the picture of the kouki axle. it just happened to be a E series diff from a tarago. This was the shape that also came out with a F series diff. (which is around 28mm diameter). My diff center was brnd new never used so is was a real tight fit. I got some lapping paste and lapped the axles to the center female spline until it was a push fit.

warning.. if your doing this with out a set of vernier calipers . GOOD LUCK!! go buy a set they are cheap and very handy

[AZA510]

The axle's i have are, Not from, a Tarago...!!

Q:- But what is the spline shape..??

BANG! here is your answer why they dont fit, just for the guys that have bought them already.

I found the tarago spline has a little bit squarer tooth then the kouki diff center spline

[styler]

yeah also had the verniers wandering around the wreckers
and they are the same od on spline so i thought it was all going to fit.

ah so you lapped them and they are a good fit, might give that one a go
as i have a spare set to mess around with.

[styler]

actually i did notice that the tarago was a more square shape compared to the splines
in the centre, maybe the needle files and some lapping paste can persude it all to work.

[AZA510]

oh yeah the square file came in handy a bit too..

[AE25]

interestingly i had a 7.1" E series head sitting on the floor not knowing what it was (til i measured the crown wheel). and found the kouki T series axle fit it nicely. maybe it was a bit worn? im not sure.
CR30 4wd vans have a kouki head in the FRONT IFS diff. so do 4wd corolla, 4wd celica gt4, rav4 etc in the rear, usually IRS. ta61/aa60 etc have both zenki or kouki.. theres a changeover year around '85-'86 like the ae86 though never come across a live axle disk diff in the A6# celica.
jdm ma45 have zenki disk diff but is wider.. need to remove about 8mm from the spline to fit te71/ae86 disk housing, and even then it runs out of spline to fit into the head. i tried this and had to use a 1mm spacer on the end of the housing so it doesnt bottom out.. would be worse with lsd fitted.
the problem with using drum T series axles to replace disk brake axles, is the shaft diameter that the bearing fits to is not wide enough to fit the disk version double row bearing and retainer.
if you ever snap the T series disk axles.. could be an idea to weld another spline on there from one of the kouki half shafts. hope its welded straight and strong! haha

[terryo]

For what its worth, I can confirm the spline shape is quite different between the E code diffs and T code diffs (apart from spline count etc). The Kouki axle will fit the E diff but not vice-versa.Cutting the Kouki spline is very difficult, and in any case, all Toyota axles of this period are damm hard. I have worn out several cutters doing one as an experiment.

[AZA510]

that sucks terry. for whats its worth I used axles out of a tarago that had E2** on the build plate. My diff was a T series diff which zenki axles did NOT fit. My diff was new and after a bit of lapping paste the axles were a push fit.

not saying your wrong we just had 2 different experiences. Mine worked and your must not have

[terryo]

what I have found is 2 totally different shaped spline sections in those diffs. from an engineering viewpoint, they dont match so they dont transmit power correctly. bad spline fit results in overloading a micro level (ie they only touch on a few points which then wear out/shatter).
I have organised to have the splines in the diff re-cut so I can use the heavy E code diff axles from a tarago etc in either of the T series diffs . This is not cheap, but the only "good" solution I have come up with.
Anyone wanting this done should email me directly. I can also shorten/modify diff housings etc

[styler]

havent got around to playing around with trying to persuade an e series axle spline into a kouki lsd yet but as terreyo says it needs to be a perfect fit to enable strength and power/torque transfer so i might give it as miss and find a kouki axle sample to repline for my lsd.

on another note, theres very few kouki axles avaliable in aus bar a few import places but people also say 4wd or ae95 wagon is the same axle spline
(not pcd or axle face, and not sure on length or bearing size)

well a day at the wreckers and redbook found :

4wd wagons:

tercel 83 - 88 : too small diameter, not even close. if it says tercel keep walking.

ae95 corolla 88 - 96 : its a lot of models!

88 model - some random code on transaxle plate, one long 3 inch stud on jap banjo diff

91 model - e series on transaxle plate, havent checked splines though yet

so its gotta be one of these?

anyone know because i cant find anything else so far...

on another note e series from any e series car does not fit, i have tried quite a few
different axles fro different cars with no luck at all, havent tried the ae95 axle yet but may be able to next week.

peace out kouki people

[Hen]

Styler, I have an AE95 axle at home which I pulled (happened to find one at pinch a part) just to check exactly this out (it fits well). I've decided to run the smaller axles and centre, so you can have it if you like. I could even cut 6" off the spline end to make it easier to send.

Drop me a PM if interested, though I won't be home for two weeks.

Hen

[Mr Revhead]

all the 4wd corollas have a T series diff.
as mentioned earlier the bearing sizes are different