yeah I got it. another way to make sure you have the star right is this:
make sure the ring has the flat side inside the cup. Put the star inside, and flip it around a couple times. With the correct orientation, the star is a little more "sunken" in the ring. The incorrect orientation will place the star up higher in the ring which causes it to lock in place and not move very much.
So just to confirm, the FSM is wrong with regards to star orientation? I marked mine before taking the Birf apart and was surprised to see it didn’t match the fsm. What they call the “protruding end” was oriented towards the birf not towards the axle as they show. Looking through the thread above it looks like how I marked it is correct, the flat end of the cage towards the birf and the protruding end of the star towards the birf. That’s quite the mistake in the fsm.
Interesting. I would also trust the marks you made. I just did this last week 1500 miles from home. Before I left, I took a photo of a drawing I'd put in my FSM at home. I marked mine as well and found things did not match the manual. It was late at night after a 16hr day and I spent about 10 minutes hemming and hawing and finally wised up and thought. "I marked these things and that's the way they're going back in." Two days later drove 1500 miles without incident, so I did what was right. But I agree with you something was amiss. The snap ring chamfer is actually how I'd describe BOTH sides of the star's center hole but they're just different chamfers. So it would be a service to others if you draw what you're finding and that may be helpful. If I drew in my FSM, it's usually because I found something in error or not clear.
I'm embarrassed to say rather than confirm something was right or wrong that night, I just stuck to my guns and did what I knew was right by trusting my marks. Perhaps others have done this as well and can help us. If the FSM is wrong, and it happens, we should be sure it's well known here because I think it will quickly damage the joint, or end up not going back together - can't recall. Anyone?
Don't forget the hose clamp trick to reassemble the birf onto the axle.