So, I've been looking for the cause of a nasty thump/clunk that happens whenever I shift quickly or turn sharply, and I noticed that my drive shaft turns about an 1/8th of a turn before my half stubs turn. Is this normal? Or do I have too much backlash?

 

That's about how much mine has and I was wondering the same thing a few weeks ago when I was putting the diff back in. I don't get any clunking or anything though, so far it seems to be working correctly.

 

I KNOW 100% THAT THE MANUAL HAS THIS IN IT.

So act like a true mechanic and look it up!

 

The manual does not say anything about how much free play the drive shaft should have.

Measuring backlash requires taking the diff apart.

 

If it's FD the manual does say as I've been through the whole process, between 0.09mm - 0.11mm.

Have a read of the FD service manual. Front & Rear axles chapter. Last few pages

http://www.rotaryheads.com/PDF/3rd_gen/

You can check the backlash with the diff inside the vehicle still. Drain the oil, remove the front cover and get a dti gauge with a decent magnetic stand and your golden although it's tricky because the rear subframe doesn't make it easy. Hope this helps

 

Just wanted to add to this. If you can't measure the backlash with a dti and the diff still in the vehicle due to clearance issues with the subframe....you could always check the ring gear contact pattern which you can do with the diff in the vehicle. It may not tell you the exact mm of backlash you have but you will clearly be able to see whether there's too much play if the pattern is way off.