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Removal/Welding/Installing Differential
Disclaimer: Don't weld your diff if you plan on just going from home to school etc. All of the steps I performed are my way of doing it, feel free to alter any steps if it's easier for you. this is a one man job but a friend could help at various points. I did this write-up for those who chose to do so. if you are against it keep your comments to yourself please
------------------------------------------------------------------------------------------------------- This is my second welded diff. the first one broke loose because i had an poor low voltage flux welder. Here it is. Tools & Material *to remove diff* http://img125.imageshack.us/img125/2...5270358ll1.jpg 17mm socket/wrench 14mm wrench 12mm wrench pry bar hammer 1/2 breaker bar floor jack jack stands wheel chock drill/wire wheel(optional) goggles(optional) Impact gun(optional) *to weld diff* http://img106.imageshack.us/img106/2...5270359rg5.jpg Mig welder ( at least 110 Volts) safety equipment chisel( thin flathead) magnet 2 bottles of gear oil 2 cans of brake cleaner RVT red,copper or black Drain pan simple green(to clean all that damn gunk/grease on bottom of car) Propane Torch ( optional) ---------------------------- Removal 1. insert wheel chocks under front wheels and place Jack under diff toward the center to raise the car http://img64.imageshack.us/img64/4424/kp5270351dq0.jpg 2. place jack stands http://img250.imageshack.us/img250/8...5270354mm9.jpg 3. if you feel a need to you can remove rear exhaust hangers to free up space http://img125.imageshack.us/img125/4...5270360bz6.jpg 4. remove sway bar mounts only ( will give you needed room to clear pinion input) http://img529.imageshack.us/img529/5...5270379kx1.jpg 5. drain fluid now or just allow it to gush out when you remove the rear cover, use 1/2 breaker bar http://img240.imageshack.us/img240/4...5270372km5.jpg 6. with the e-brake up, proceed to remove the 6 12mm bolts from the half-shafts, you will have to let the e-brake down in order to rotate the half shaft and get the others. http://img159.imageshack.us/img159/8...5270367vk4.jpg 7. once you have removed the bolts, you will need the pry bar to remove right half shaft (only) due to notch http://img131.imageshack.us/img131/2...5270369fe2.jpg 8. Remove 4 bolts from drive shaft, you will need a buddy to pull and release e-break or use thin rod or long 3/8 extension. http://img184.imageshack.us/img184/4...5270378oa3.jpg 9a. before removing the 4 nuts that bolts the diff to the rear sub frame,you may have to blast rust off so that you will not strip the nuts like so. http://img443.imageshack.us/img443/32/kp5270376xd4.jpg 9b. after you do that proceed to remove them using the following methods. http://img255.imageshack.us/img255/2...5270373aw8.jpg you will need shallow socket to get upper bolts with breaker bar due to gas tank http://img65.imageshack.us/img65/1662/kkp5270374yg1.jpg 10a. Place jack toward back of diff like so, and lightly jack the diff against the tunel http://img184.imageshack.us/img184/884/kp5270390pl6.jpg 10b. remove two 17mm bolts holding diff to sub frame http://img163.imageshack.us/img163/6...5270365nn9.jpg 10b. place hand in this position, with your elbow bent at 90deg angle and slowly lower diff http://img114.imageshack.us/img114/6...5270396yo8.jpg Welding 1. Remove bolts from diff http://img174.imageshack.us/img174/9...5270398mt2.jpg 2. use pry bar with hammer to remove cover ( be careful) http://img443.imageshack.us/img443/2...5270400ty4.jpg 3. Clean up rear cover and apply liquid gasket. do this now and it will be very firm during re-installation http://img131.imageshack.us/img131/5...5270403by3.jpg 4a. As you can see the gears are coated with oil ( a good thing lol) but you must dry them using brake cleaner before you can weld. spray the spider gears only, don't directly spray the Ring and Pinion gears http://img116.imageshack.us/img116/6...5270405vw6.jpg 4b. After about 2 min, the gears will be dry and look like this. pour the brake cleaner out or else you will get an fireball.( optional but recommended)Take and wet towel cut into strips and insert inside of bolt holes and around bearing like so to protect against sag. also the pieces on the bearing will have to be soaked at least 2-3 times because the heats will dry them up and catch fire. http://img113.imageshack.us/img113/7...5270409tk6.jpg 5. With-in the enlarged portion of the picture, you want to fill the section with the orange line in first with a nice strong continuous bead. the area with in the red circle must be filled/joined in order to increase strength. depending on your spool size, you may need a second. i used one spool per side. you will repeat this action 3 more times on this side and you must rotate the diff and complete the other side. IF you have a Propane torch pre heat the gears before welding http://img112.imageshack.us/img112/7...5270407qt4.jpg 6. once you have welded the corner of all the gear, for extra strength you want to run about two to three layers of continuous bead all the way around, start low and build your way up. i didn't get a picture of the underside of the Ring Gear but it is welded the red line is imaginary, every once in a while use your flathead chisel to knock loose sag away, http://img124.imageshack.us/img124/5...5270419yv7.jpg 7. once you are done welding, pour a bit of gear oil on the gears becuase now you may have to un-seize them.. don't get scared.. the gears are stiff because there was no fluid present when you are welding and the heat gets pretty high. All you have to do is place a 17mm wrench on the bolts of the Ring gear and give it a few manly taps and it will free up again an began to spin freely 8. now take your second can or brake cleaner and blast all of the debris out very good. you don't want sag getting into your bearings. If you have the magnet it will be awesome for getting all of the metal shavings and sag out of the differential carrier. now empty the mixture of gear oil and brake cleaner from the diff housing 10. after you think you got enough of it out, pour one bottle and an half of fluid inside the diff while the cover is off, this will make life a little easier lol 9. Clean the matting surface on the differential housing using a little brake cleaner and a scraper if need be and place rear cover on and follow color/number pattern http://img443.imageshack.us/img443/3...5270420cw8.jpg Installation 1. Position diff under car, rest the pinion input on the sway bar like so ( if you don't have a buddy to pick it up for you while you jack it up) http://img19.imageshack.us/img19/9650/kp5270423my7.jpg 2. Now you must lift the back of the diff up and place jack under diff. it will help if you have the jack already preset to a pretty decent hieght. the diff is really easy to handle with the front end of it resting on the sway bar. http://img79.imageshack.us/img79/5800/kp5270424yg4.jpg http://img69.imageshack.us/img69/5327/kp5270429lj0.jpg 3. once you have the 4 bolts through, lightly jack the diff against the body of the car. and insert the two 17mm bolts at the front of the diff. but don't tighten them all the way becuase you have to fully tighten the diff cover bolts first. the reason being is, you want the cover as flush as possible against the sub frame. follow the color pattern, you can start on any nut that you wish. http://img251.imageshack.us/img251/3...5270366gh8.jpg (trick: you can double a wrench up to increase the amount of TQ you can apply) http://img238.imageshack.us/img238/6...5270433rw5.jpg 4. now completely tighten your 17mm bolts at the front of the diff 5. now move your half shafts back into place. in order to line the bolt holes up you will have to release your e brake and rotate your wheels becuase the diff will be hard to turn now. remember our notch on the right side?? you will need to place the notch above the half shaft like so and use your pry bar to pop it back in. http://img105.imageshack.us/img105/7...5270435oo5.jpg 6. now you will insert all of the bolts back into the half shafts on both side ( 12 in total) http://img69.imageshack.us/img69/3324/kp5270436dd8.jpg 7. Next you will you will re-attach the drive shaft like so. you can have buddy release/pull the e-brake so that you can rotate the wheel and rotate the bolt holes on the pinion input for easy access/tightening http://img411.imageshack.us/img411/498/kp5270440km5.jpg 8. last step will be to reinstall sway bar bushings using 14mm wrench and if you have as much gunk and grease like i did you are going to soak the car with simple green and blast it all off with pressure washer. Thank You for Viewing and go get sideways http://img.photobucket.com/albums/v2...s/HPIM0645.jpg http://img211.imageshack.us/img211/7771/coolaidaq5.png |
Originally Posted by Biggamehit
(Post 311631)
write up will be up tonight :beerchug:
Not even a sneak preview.... |
Dude, keep us updated, i was thinkng of installing a dif myself, like to see how its done first... thanks.:D
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LIES! It's 1:37am (central) and I see no write up!
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221 here and stillll no write up....
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Cmon guy's cut Bigg some slack... He was probably up late having a good time with some ladies and a few drinks.
It's only 12:39AM over here in Cali..... |
Well me and Cronux are over here on Chicago time. And since Chicago beat LA for the U.S. 2016 Olympic bid today we shall go by Chicago time. Either way he's still late!
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LOL... you win....
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i've been popping in and out of here every few hours since yesterday and still no write up.
i''m sure there's a go reason though. he's gone awol!!!:lol: |
I bet the air force sent him on some super top secret reconnissance mission with short notice. Of course, thats not what he'll tell us, or the government will have him murdered.
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OMG buddies you would not believe what happen last night man......
on the way out of the shop i was closing our door and this HUGE DOOR feel off the track and all most murdered me.. luckily with my Linebacker quickness I was able to quickly step back while punching the top of the door away from my head, i have a bruised hand and arm thats about it. I could not leave the shop unsercure like that so became a guard for the night.... However i did manage to drift around our lot a few times LOL. which has a nice S turn.... Im on the way home now to start the write up... IM soo sorry guys here is the proof http://img239.imageshack.us/img239/1...0445sz3.th.jpg http://img110.imageshack.us/img110/9...0444lr2.th.jpg http://img409.imageshack.us/img409/3...0443zj0.th.jpg |
:p
Originally Posted by Biggamehit
(Post 311765)
OMG buddies you would not belive what happen last night man......
on the way out of the shop i was closing our door and this HUGE DOOR feel off the track and all most murdered me.. luckly with my Linebacker quickness I was able to quickly step back while punching the top of the door away from my head, i have a brused hand and arm thats about it. I could not leave the shop unsercure like that so became a guard for the night.... However i did manage to drift around out lot a few times LOL. which has a nice S turn.... Im on the way home now to start the write up... IM soo sorry guys. That sucks, except for the drifting parts, hehe. Were the cars ok?:cool: |
yea luckily i didn't pull my work car ( 300 Chrysler) back into its normal spot we just got them about a month ago
im working on write up right now... ill try to have it done by tonight. Ill be adding piece by piece until its done |
hahahahahahahahahahahahahahahahahahahahahahaahha
wooooooo |
Originally Posted by Biggamehit
(Post 311765)
luckily with my Linebacker quickness I was able to quickly step back while punching the top of the door away from my head
punching down garage doors and drifting while guarding the sacred shrine...so baller |
LMAO
when i was looking at the pix...... i put something together.. you see where the door folds over,, im 5 10'' Insert my skull there, that would not have been pretty. |
nice write up man. your an ucking G. diy welded diffs ftw!
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ha
thanks man bro i forgot to tell you i was check out your garage240sx.com i like it man |
great write up. i would just like to add something if you don't mind.
you said that the fist diff. broke because of the low voltage of a flux welder. but the mig welder you used uses flux also but it's within the wire. arc welders have the electrode covered in flux. the opposite of mig wire welders. with two welders of the same amp rating one mig and one arc you can achieve stronger welds with the arc welder. this is because the rod burns hotter and results in better penetration. the other mig welders with shielding gas give you better looking welds but they are not as strong as the welds of and equally powered arc welder. sorry if i went off topic i just wanted to let you know. |
im aware for my personal use buddy, but i didn't want to get into welding here. i will leave that up to the person. if they are going to attempt to weld their diff i would hope they would either give it to someone else or look up metal properties.
i could actually see the metal melting and fusing together. i knew before the last one even broke that it would. there was no penetration at all im willing to bet an 500 dollar mig welder is better than an 145 dollar flux welder. the amps are higher thats all im worried about. very good insight bro and reader, read up on different welder properties and metals. utilizes flux core wire of course but this is not a MIG welder ( what i used before) http://www.affordabletool.com/sess/u...01_400x312.jpg look at the amazing variable voltage LOL http://www.affordabletool.com/sess/u...-welder-02.jpg |
got it i thought you were getting a tig welder though?
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yea i am.. the Lincoln welder is not mine, its a buddies. i need to pay back college money so somethings were put to the side lol
so i can make more money in the AF |
that is one niceeee how to
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dude your doin mine lol
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ha ha ha. na you will do it, ill watch with the whip in my hand just to make sure you follow the steps lol.
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haha i dont know if i can lay down the beads like you i only welded once and it was horrible btw hows it feel like on the road
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nice write up bro. lol you need to start a lil garage company.
have ppl send u ther diffs u weld them up. u could make some dough lol. |
I'm gonna weld my diff!!!!!!!!!!111one
LOL! I think only DJ would know why that would be funny on my car. HAHA! -Dave |
nice write up, i swapped out my diff for a j30 vlsd on my s14 but the s13 diff looks a bit tougher to do but for the most part the same as a s14.
or maybe its just me cause i was lucky enough to use a lift, tranny jack and airtools |
Originally Posted by Biggamehit
(Post 311820)
ha
thanks man bro i forgot to tell you i was check out your garage240sx.com i like it man |
Originally Posted by sr91240
(Post 312083)
haha i dont know if i can lay down the beads like you i only welded once and it was horrible btw hows it feel like on the road
nice write up bro. lol you need to start a lil garage company. have ppl send u ther diffs u weld them up. u could make some dough lol. |
tig is nice and precise, but its too slow... (imho.) i mean, a good tig welder can weld 2 razor blades together, but it takes a while. a high power mig can make welding go lightning fast. *this is also in my experience. our mig at school rocks. well so does our tig. and our arc.
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Understood.. im still learning. yea i like mig's i have yet to use the gas, i wonder how that will be?
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I'm gonna lock my diff using telepathy and pyrokenetics
-Dave |
Originally Posted by USMCDrifter
(Post 312192)
I'm gonna lock my diff using telepathy and pyrokenetics
-Dave |
Originally Posted by jramosthe1st!
(Post 311847)
you said that the fist diff. broke because of the low voltage of a flux welder. but the mig welder you used uses flux also but it's within the wire. arc welders have the electrode covered in flux. the opposite of mig wire welders. with two welders of the same amp rating one mig and one arc you can achieve stronger welds with the arc welder. this is because the rod burns hotter and results in better penetration. I only prefer ARC welding with 9~25PSI of argon depending on the ARC voltage and the gauge of steal I'm using. By FAR the welds look clean and professional with no bird looking poo drops.... It is a sun of a ***** that if you don't use enough flux on the tips and you bead weld a lot it can crack, which is the only down side to the ARC. It's just a matter of practice makes perfect... |
i got you..... i guess ill just stick with powerful mig"s. i have buddies who have had an single diff for 4 years lol with tons of miles on them.
yea i got more practice and laying single beads... its beginning to be alot of fun |
Excellent write-up. I was going to buy a VLSD but if I can get my hands on a welder, I'm gonna do this instead. I thought that it would be more difficult than that. Thanks!
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sure thing very easy... if u start early in the day.. you can be out driving it around by say 12pm if you really hustle.. each time i have removed the diff, it only takes about 2 hours or so.
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2 Attachment(s)
Sorry for digging up an old How-To, especially since it is my first post on these forums.
Attachment 20148 Attachment 20149 ^ See? Vince and I followed your directions and had great success. I just wanted to give a big THANK YOU to Mr. BIGGAMEHIT for the tutorial. Also, thank you to BIG VINNIE, for his welding expertise. The diff goes in tomorrow, and I'd be happy to give a wee bit of a my first impressions if anyone is interested. Thanks again, guys. :smilie_thumbsup: |
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