If first you don't succeed ... use a bigger hammer. (Differential removal and LSD install.)

FixedWing · 01-13-2006, 06:47 PM

Today was a much better day (see link for yesterday's thread). I managed to get the differential disconnected from the drive shaft with only another 10 minutes of work under the car.

The photo shows the drive shaft flange with the two damaged bolts still attached. Even with the unit off the car these bolts still did not want to come out! :-/

I spent the rest of the day cleaning up the differential, swapping parts, installing new bearings, installing new seals, etc.

One seal was leaking. Neither were in particularly good shape. Both needed replacing. I did notice a coating on the wall of the differential case. The magnet had metal also. When I looked at the old bearings I didn't get the impression that they were in that great condition. Granted this unit has 146,000 miles on it, but I had expected it to be in better condition inside.

My conclusion is that these differentials are probably running a lot hotter than we realise and that the bearings are probably under a significant load. My diff ran the original fluid for the first 134,000 miles. Then I switched it to Redline 75W90 Gear Oil. I think my advice would be to swap the fluid in these units regularly.

The driveshaft portion of the differential seemed to be in good shape so I decided not to rebuild that.

I'm waiting for a couple of items. I'm hoping I can get it all back together and in the car tomorrow.

It certainly is nicer when things go well.

Stephen

Another frustrating day under the S4. :-/

Imolavirus@BuehnEngineering · 01-13-2006, 06:52 PM

FixedWing · 01-13-2006, 06:52 PM

FixedWing · 01-13-2006, 06:53 PM

CTAUDIDUDE · 01-13-2006, 07:01 PM

FixedWing · 01-13-2006, 07:07 PM

Never had to resort to the come-along.

Stephen

CTAUDIDUDE · 01-13-2006, 07:10 PM

Ochlockonee · 01-13-2006, 07:12 PM

FixedWing · 01-13-2006, 07:15 PM

The side that gave me trouble was the side with the good seal. The side with the bad seal was sufficiently coated in oil which protected it from corrosion.

:-/

Stephen

Dr. Jekyll · 01-13-2006, 07:27 PM

01-13-2006, 06:47 PM	#1
FixedWing AudiWorld Super User Garage is empty, add now Join Date: Dec 2003 Posts: 7,155	If first you don't succeed ... use a bigger hammer. (Differential removal and LSD install.) Today was a much better day (see link for yesterday's thread). I managed to get the differential disconnected from the drive shaft with only another 10 minutes of work under the car. The photo shows the drive shaft flange with the two damaged bolts still attached. Even with the unit off the car these bolts still did not want to come out! :-/ I spent the rest of the day cleaning up the differential, swapping parts, installing new bearings, installing new seals, etc. One seal was leaking. Neither were in particularly good shape. Both needed replacing. I did notice a coating on the wall of the differential case. The magnet had metal also. When I looked at the old bearings I didn't get the impression that they were in that great condition. Granted this unit has 146,000 miles on it, but I had expected it to be in better condition inside. My conclusion is that these differentials are probably running a lot hotter than we realise and that the bearings are probably under a significant load. My diff ran the original fluid for the first 134,000 miles. Then I switched it to Redline 75W90 Gear Oil. I think my advice would be to swap the fluid in these units regularly. The driveshaft portion of the differential seemed to be in good shape so I decided not to rebuild that. I'm waiting for a couple of items. I'm hoping I can get it all back together and in the car tomorrow. It certainly is nicer when things go well. Stephen Another frustrating day under the S4. :-/ __________________ ================================================== ======================

01-13-2006, 06:52 PM	#2
Imolavirus@BuehnEngineering AudiWorld Super User Garage is empty, add now Join Date: Mar 2002 Posts: 17,943	Glad to see it finally came out for you :) __________________ -Jacob ^^^CLICK SIG FOR BUEHN ENGINEERING WEBSITE^^^ <big><big>Website Here!!!</big></big> <big>Items For Sale</big>

01-13-2006, 06:52 PM	#3
FixedWing AudiWorld Super User Garage is empty, add now Join Date: Dec 2003 Posts: 7,155	Need more proof of the corrosion? This is even after i'd cleaned up the part! Six years old. :-/ __________________ ================================================== ======================

01-13-2006, 06:53 PM	#4
FixedWing AudiWorld Super User Garage is empty, add now Join Date: Dec 2003 Posts: 7,155	Me too! :-) __________________ ================================================== ======================

01-13-2006, 07:01 PM	#5
CTAUDIDUDE New Member Garage is empty, add now Join Date: Nov 2005 Posts: 447	Did you keep hammering on it or use the come-along method? __________________

01-13-2006, 07:07 PM	#6
FixedWing AudiWorld Super User Garage is empty, add now Join Date: Dec 2003 Posts: 7,155	I could see it move slightly so that invigorated me! A little more effort and it was out. Never had to resort to the come-along. Stephen __________________ ================================================== ======================

01-13-2006, 07:10 PM	#7
CTAUDIDUDE New Member Garage is empty, add now Join Date: Nov 2005 Posts: 447	Nice! Glad to hear you got it apart. __________________

01-13-2006, 07:12 PM	#8
Ochlockonee Member Garage is empty, add now Join Date: Mar 2004 Posts: 2,951	You clearly need more fluid leaks under your car for corrosion protection :-p __________________ "No, a flux capacitor is not compatible with a ham sandwich."

01-13-2006, 07:15 PM	#9
FixedWing AudiWorld Super User Garage is empty, add now Join Date: Dec 2003 Posts: 7,155	Actually, you are right. The side that gave me trouble was the side with the good seal. The side with the bad seal was sufficiently coated in oil which protected it from corrosion. :-/ Stephen __________________ ================================================== ======================

01-13-2006, 07:27 PM	#10
Dr. Jekyll AudiWorld Super User Garage is empty, add now Join Date: May 2004 Posts: 7,719	Congrats! Too bad you can't make it to the gtg tomorrow though. __________________

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