Hi All,
As per the subject this is a tutorial on how to repair your intermediate shaft, yes, even if you have a VR4.
I would like to invite Koray (TRQ-STR) to provide feedback as this is my version and installation differs depending on knowledge. (Mainly for the cordia installation)
Firstly, the VR4 shaft won't fit the VR4 block with a cordia gearbox, you will have to shave down the carrier bearing mount to suit, I did this on a "dummy" engine and all worked fine, put in my car only to find intermediate turning of the opposite wheel in the same direction after a few drives.........Humm..........not right.
After some investigation I found the centre carrier bearing was allowing horizontal movement allowing the diff to lock, the deflection of the bearing was up to 6 - 8mm at the transmission end of the shaft on the overall rotation, allowing 1-2mm at the bearing cup.
Here is how to repair:
Grab a bearing/gear puller and remove the carrier bearing from the shaft, If you don't have a puller you can use a 14LB hammer with the carrier in a vice.
Remove both of the oil seals.
Time to remove the bearing, you can either press it out or just use bruit force with a large hammer. (If the bearing is stuffed so who cares)
Clean the carrier housing to ensure no rust or grit is evident.
Paint the housing (If required........don't forget to etch primer as paint won't stick to the cast)
Use 800 git to remove the rust where the bearing was seated, paint the driveshaft axle (Where required)
To install the bearing, this can either be pressed in or if you know what you are doing, hit in with a hammer, if you choose the latter make sure you use an "old" bearing and slowly hit down at regular intervals, take your time.
Bearing installed.
Add the rear oil seal. (Don't forget to add wheel bearing grease)
OK, time to add the shaft, now this can be pressed in, or if again you know what you are doing, use a hammer at the circumference to ensure constant pressure without ruining the bearing, once home should look like this:
Rear of the axle in home position.
Install the front oil seal and your finished, install back in the car.
After repair if you spin either wheel (in gear) the adjacent wheel will easily spin in the opposite direction, as I don't have an LSD.
spec savers will be expecting me.