I have been using information from the Forum for a long time but this is my first "build" post. I am a "home" mechanic and all self taught by searching and reading and asking questions if needed but when it came to building my axles for my 6 speed manual swap I was a bit stuck on the process. As I had not found any detailed posts on this I thought it was my opportunity to help other Noobs who need some steps and pictures to make this easier for them. Archie helped me as well with answering my dumb questions so hopefully this will help others who won't have to ask the same ones.

First I laid out all the parts...



- reman axle shafts - part 60-1114 - must not be NEW as those seem to all be a smaller (cheaper) shaft size and will not work for this rebuild. Search for these locally or online but note that I ordered 4 before getting 2 that were correct (returned the others). I ordered the same part each time but I think as they are reman there are many times a slightly different part gets in a box with this part number…painful but eventually I had 2 that matched and were reman originals. Also note, I used 2 short shafts (driver side) as you are only going to use the threaded end for the hub side so you don't need to get 1 long (pasenger side) and 1 short….but you can.

- Axle parts provide by the Archie kit - 1 driver side and 1 passenger side. I assume these are a custom part.

- CV boot grease - I used Dorman 614-066
- CV boot clamps - 20 pcs bag SS Adjustable CV Drive Axle Joint Boot Clamps 48 mm and 120mm (Amazon). You only need 2 large and 2 small but as it was my first time doing this the 20 pcs set was not much more so I went for more.
- Tools - boot clamp crimper (Lisle 30800 CV Boot Clamp Pliers) , Channellock pliers

Steps
- start with 1 of the reman Fiero axles on the threaded end


- Cut off both clamps using side cutter pliers




- Pull boot back towards other boot to get it out of the way


- Clean out some grease to see the lock ring


- Use Channellock pliers to EXPAND the lock ring and at the same time pull the CV joint off the spline


- Remove the boot and place it onto the new F40 style axle


- Add grease as needed into the CV joint

- push the outer CV joint onto the new F40 axle


- Pull the boot over the outer joint and position both for clamping


- Position the clamp, snap it into place by hand into the notches then use the crimp tool to complete the band


- completed first Axle (lower) with old Fiero Axle (upper) with CV joint removed


- completed new CV joint on first Axle


- The first Axle (first try ever) took me just over an hour. The 2nd axle I completed in 15 mins. Both completed axles below.


Hopefully these steps and pics help someone else like so many PFF posts have helped me.

Ken

*First*

The *shafts* are custom, but the inner CV joints are standard parts.

It's not even necessary to have a custom right shaft, as the G6 axle can be mix/matched with the stock Fiero axle to make one that works from all shelf parts. The "spider" and "cage" from the G6 outer CV joint must be swapped into the body of the Fiero outer joint, but that's all that's necessary.

However, the custom shaft is necessary on the left side, as that shaft ends up being shorter than any standard shaft.

You could also use Coboltt SS axle on the left side. A G6 drivers side axle with a Fiero outer hub on the right with the Cobolt ss half shaft for perfect length. Transmission stock location. G6 axle is 1" longer than Cobolt axle.

So Will, are you talking about the G6 6 speed 33 spline shafts or the G6 6 speed 34 spline shafts?

Also what is the left to right placement of the face of the G6 transmission from the centerline of the cradle

Archie

quote Originally posted by Will: *First* The *shafts* are custom, but the inner CV joints are standard parts. It's not even necessary to have a custom right shaft, as the G6 axle can be mix/matched with the stock Fiero axle to make one that works from all shelf parts. The "spider" and "cage" from the G6 outer CV joint must be swapped into the body of the Fiero outer joint, but that's all that's necessary. However, the custom shaft is necessary on the left side, as that shaft ends up being shorter than any standard shaft.

What I did and recommend especially if you have never done this before is get the kit from Archie . With this small customization above and following his great instructions included in the kit the F40 install has been very straight forward.

k

quote Originally posted by Archie: So Will, are you talking about the G6 6 speed 33 spline shafts or the G6 6 speed 34 spline shafts? Also what is the left to right placement of the face of the G6 transmission from the centerline of the cradle Archie

Why ask a random internet smartass? Don't you know what you ordered?
Maybe you should go to his house and check.

Spline count isn't terribly important either way it's done, as--since you obviously haven't read the way everyone else does the F40 swap--splined components don't get mix/matched.

The Cobalt axles mentioned above are from the first year Cobalt SS and Saturn Redline up to 07. 08 and up or whatever year they switched to turbo, the axles were upgraded to the standard used with the G6 F40 combo.

Let's see, some internet smartass jumps into a thread & makes an inaccurate statemant as if it is a proven fact.

That same smartass must not know that midway thru production of the G6 6 speed GM made a change in the axle shafts & internals at each end. They changed from 33 to 34 spline. Yet GM didn't change the part numbers of the assemblies.

I wonder if he knows that there is nearly an Inch difference in the OEM axle lengths between the 33 & 34 spline shafts?

Most likely he doesn't know or doesn't care about the accuracy of his statements.

With 92 6 speed kits sold & 36 of those assembled in house, I'd say some still have a lot to learn.

When you guys get to the 36 6 speed cars assembled & on the road, then maybe you'll be able to answer my questions.

Archie

quote Originally posted by Will: Why ask a random internet smartass? Don't you know what you ordered? Maybe you should go to his house and check. Spline count isn't terribly important either way it's done, as--since you obviously haven't read the way everyone else does the F40 swap--splined components don't get mix/matched.

Your questions aren't relevant to those of us who aren't buying anything from you.

Aww, that's cute, you've built a few cars with horrendous NVH characteristics. I've built things that are in orbit. Where's the measuring tape?

quote Originally posted by Archie: Let's see, some internet smartass jumps into a thread & makes an inaccurate statemant as if it is a proven fact. That same smartass must not know that midway thru production of the G6 6 speed GM made a change in the axle shafts & internals at each end. They changed from 33 to 34 spline. Yet GM didn't change the part numbers of the assemblies. I wonder if he knows that there is nearly an Inch difference in the OEM axle lengths between the 33 & 34 spline shafts? Most likely he doesn't know or doesn't care about the accuracy of his statements. With 92 6 speed kits sold & 36 of those assembled in house, I'd say some still have a lot to learn. When you guys get to the 36 6 speed cars assembled & on the road, then maybe you'll be able to answer my questions. Archie

quote Originally posted by Will: Your questions aren't relevant to those of us who aren't buying anything from you. Aww, that's cute, you've built a few cars with horrendous NVH characteristics. I've built things that are in orbit. Where's the measuring tape?

That's a pretty lame response, even for you.

My questions are relevant when responding to your uninformed statement as being fact when it was not.

You don't need to respond, we already know that you didn't have the facts when you made your statement.

BTW, just because you can't find that that rocket you fired off in the backyard, doesn't mean it achieved orbit.

Archie

You guy's miss the point of learn all about the different ways axles can be mixed, shortened and custom made to work on our fiero's. This isn't a match about who's more correct. Nobody cares. If you have information that will help someone that's what is important. Save the bigger man stuff for some where else. we all come here to learn not for BS.