Quote Originally Posted by 89Vette View Post
Because it's such a common problem, I wanted to get your attention. In researching the halfshaft options, I saw EMPI, A1-Cardone, OEM, and rebuilders as the viable options. And, it sounded like EMPI was the best aftermarket choice -- without breaking the bank.

Still, I was troubled by this ball-size issue. I saw at least one post (that I can't find now) where the writer was adamant about EMPI's being problematic. Moreover, I've questioned the viability of those shafts -- if the balls really weren't the same size as stock. I just couldn't see how they'd ride in the tulip w/o making some noise -- whether popping, binding, or vibration.

To add to the concern, at least a few posters complained of their results -- especially if their rig was lifted. So....today was the day to get mine installed.

I had a shop do the work for me because I wanted it done before my surgery. Plus, I still wasn't sure how much of the steering knuckle/backing plate needed to be turned loose (from parts like the sway bar, end-links, etc...

This post is to say I got lucky.

The shop ignored the instructions I provided from this site. In those instructions, I hand-wrote a few notes -- including my wish to have the ball size checked. But, they didn't.

The lucky part came when one of the two front R1Concepts (drilled/slotted) rotors I'd sent for -- was defective. Yes...they screwed up and reamed out the holes that bolt the rotor to the hub. You could JUST BARELY see thread in the bolts holes AND the bolts would drop right through. IOW, no way for us to even re-tap them.

So, after waiting an extra week for R1Concepts to deliver their goods, they let me down.

I scrambled, left work, got another set of rotors and went to the shop. I ended up getting to talk directly to the mechanic. During our conversation, I asked about the ball issue. He said one side was already installed and was fine...though presenting a mild amount of play. We finished discussion of the rotors and I headed to the front desk...where I asked a few more questions about another issue/two.

During that time, the mechanic finished pulling the opposite half-shaft. He came up to the front and exclaimed his concern about it's viability. It fit looser than the first (DS) shaft. At that point, I insisted we pull those inner cages apart and measure the balls. We found the EMPI's smaller! And, it was clear to me they should NOT be considered an exact replacement. I really wasn't even willing to use them -- and the shop agreed. You should have see/felt the slop!

But, where could one find viable shafts in 1-2hrs in ANY local city? I'm guessing you can't....Or, you'd have to take a chance on salvage or Cardones. Neither would warm my cockles after spending so much on labor.

After a bit more debate/inspection, I came up with a plan. I realized the OEM 6-ball race/retainer HAD to be reused. The EMPI was at least a few thousand's thinner and the snap ring would have been problematic. So, by reusing the OEM balls, cage, and EMPI retainer, we transfered the OEM balls to the EMPI shaft. The difference in fit/slop was night/day. The OEM balls -- on the EMPI shaft -- fit as snug as a bug in a rug!

So, if you buy EMPI shafts, I must emphasize my recommendation to follow suit. Don't use the EMPI balls. (I have to assume the Cardone's should be considered in the same light.) Otherwise, I can easily see how you'd end up with noise, vibration, popping, and all types of problems with an ill-fitting joint. With a lifted VX, it's clear why you'd get popping/binding.

Unless it's a complete emergency, I say just don't use the EMPI balls! They're just not big enough. Everyone needs big balls!






BTW: I have to consider myself lucky that R1Concepts sent me crap. Had that not happened, I wouldn't have gone to the shop...and drawn their attention to the issue, and tonight I would be one unhappy camper.

So I replaced my OEM half shaft with the recommended EMPI shaft last November. My VX is lifted about 3" and the vibration and popping started almost immediatley after the swap. After seeing this thread I decided to pull out the EMPI and replace the balls and cage from my OEM axle I still had. I measured the balls while they were out. EMPI is at 19.8mm and OEM at 20.6mm. So the EMPI is definitely smaller. But here comes the problem; the EMPI retainer uses a snap ring in the cage to hold it in (as noted in the original post), but the OEM cage has a machined lip in it to fit the OEM retainer. Long story short, the EMPI retainer did not fit in the OEM cage.

89Vette, how did you get these to fit together? After failing on that front I noticed that no combination would work. I couldn't even use the larger balls from OEM and the rest of the EMPI stuff because the holes in the cage are too small. So maybe you can shed some light on that.

Anyway, I ended up cleaning and rebuilding the OEM half shaft. The only reason I replaced it was because both boots were torn and I was told it was easier to just replace the entire shaft. I figured I would rebuild the OEM eventually and use it as a spare.

I posted some pics of the EMPI retainer. Note that the EMPI shaft was installed for only a few monthes and the retainer has been badly dented from the balls, and of course this damaged the inner green cup as well on one of the splines. I have only been doing on road city driving since replacing the shaft so this is regular wear. No off roading or drag racing. I can only suspect that the EMPI unit would have become useless in less than a year while also destroying the OEM green cup.