818 axle shaft specs

[Triathletedave]

Needing help as I cannot find the part or the engineering specs for my broken axle shaft. I am trying to replace a broken axle shaft for the 2005 Subaru Impreza 2.5 RS with no luck so far. Factory Five no longer makes the part, and I do not believe that they will share the engineering drawings. Anyone know where I could source axles or the .STL or .STEP engineering specs for the axle? Reverse engineering the part could get pricey.

Thanks in advance.

[blomb11]

I believe people on this forum have had success using the The Driveshaft Shop to get custom axles made. You would need to specify the different splines on the inner and outer to match based on your rear outer CVs and what transmission you have. This shop is familiar with Subaru should they should know the spline counts.

https://driveshaftshop.com/product-category/cv-axles/subaru-axles/wrx-axles/2003-2007-wrx-axles/

[Rob T]

I got mine at DSS. Was able to spec both ends and the length. Worked perfectly.

[driveslikejehu]

I have spare FFR supplied axles if you need them.

[lpmagruder]

Are these more or less guaranteed to eventually break? I've seen quite a few reports. I'm still rocking the ones that came with my 2014 kit and have quite a few autocrosses on them. Wondering if I should go ahead and get a set of spares made.

[J R Jones]

TADave,
I have altered my 818 project to Acura V6 powertrain and will not use my 818 reworked axles or my aftermarket suspension bits.
My axle splines are outer (M) 24 count and inner (FM) 25 count.
jim

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[Dave 53]

My experience is the FFR axles are stronger than the 5 speed third gear and pinion gear.

[Bob_n_Cincy]

I twisted and sheared off a couple of axle shafts that came with my early kit.
FFR sent me a set of pre-assembled half shafts that have held up fine. Not doing any wheel-hopping launches anymore.

Here are my notes on that FFR assembly.
Inner Joint: 3 rollers, 23.6mm male spline, 29 teeth, snap ring holds 3 lobe carrier
Outer Joint: 8 balls, 23.6mm male spline, 29 teeth, spring clip for 8 ball carrier
Boot clamp to clamp distance: 335mm
FFR axles are 20.875" long

somebody posted this picture 215289

[aquillen]

I posted the pic just above while I had both in hand from FFR.

[RPGs818SNA]

TriguyDave,

FFR sent me 2 bare axles, their part number 80237, for my 2006 Impreza non-turbo donor build, even though I ordered and received 2 fully assembled axles. Is that the number stamped on your broken axle, or listed in your parts list? They are probably no stronger than yours, but I might be able to help you get back on the road a little quicker while ordering a stronger one.

RPG

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