[Es2] Re: V8 torsen rear diff on coupe S2

[Bernie Benz]

Elijah,

I'm a Digest lurker on this es2 list, but can't lurk without comment about
your subject "how to" swap instructions.  Are you not mixing parts from two
different shim matched assemblies without mention of the absolute necessity
for reshimming?  Check the final drive assembly procedures in any Bentley!
This is no simple task, and absolutely essential to the successful overhaul
of any Hypoid final drive.

Bernie

> Message: 1
> Date: Mon, 20 Jun 2005 20:14:16 EDT
> From: Elijahallen92 at aol.com
> Subject: [Es2] V8 torsen rear diff on coupe S2
> To: es2 at audifans.com, billzcat1 at hotmail.com,
> contact at euro-audi-parts.com
> Message-ID: <a0.2acde754.2fe8b5d8 at aol.com>
> Content-Type: text/plain; charset="US-ASCII"
> 
> 
> Ok guys, this seems like a very good upgrade for our cars, especially the
> ones making big power because of wheel spin coming out of corners. This was
> posted on the S2 forum and the directions look pretty straight forward. I
> would  
> like to do this but don't have time and or the right equipment/knowledge to
> feel  comfortable doing it. Anyone out the want to whip up a batch of these?
> There  have been so many custom group buys lately I thought maybe someone
> would 
> like to  do this one.
> 
> Elijah
> 
> 
> 
> Here's a small how-to on swapping the open S2 diff for a V8 torsen  one.
> 
> I'll start this at the point where you have both diffs in front of  you on
> the bench.
> 
> - Drain all the oil from both diff's
> - Remove both  the driveshaft flanges from both diff's
> - Remove the casing-cover that sits  behind the driveshaft flange, on both
> diff's. That casing is bolted to the diff  housing itself with 9 bolts.
> - Remove both diffs out of it's housing
> -  Then remove the O-ring seal at the far end of the diff housing from both
> the V8  diff and S2 diff.
> The reason for that; is that one of the two driveshaft  flanges from the S2
> is different then from the V8. The V8 driveshaft flange has  a thicker
> diameter 
> at the point where it seals with the O-ring. We need the V8  driveshaft
> flange eventually on the S2 diff housing.
> These O-rings are metal,  and are pressed in the diff housing. They can be
> removed by driving them out  with a pendriver and a hamer from the inside out.
> Ofcourse it will be better  to replace the V8 O-ring with a new O-ring. Just
> make sure its not damaged if  you use it or dried out.
> - Press the V8 O-ring in the S2 diff housing. You  will notice that the
> inside diameter from the V8 O-ring is bigger then the S2  O-ring.
> 
> - Passing on to the diffs itself.
> - Remove the crown wheels  from both diff's (bolted with 10 bolts). And swap
> them around. So S2 crown wheel  onto the V8 Torsen Diff. Retighten the bolts
> at xx NM (will need to check what  NM's I tightened the bolts)
> - Drop the V8 Torsen diff in its new S2  housing
> - Make sure all bearings are clean. Apply some liquid gasket on the  surface
> where the casing-cover meets the diff casing. Then put the casing-cover  to
> close the diff again.
> - Retighten the 9 bolts
> - Mount the V8  driveshaft flange on the side were you swapped the O-ring
> And on the other  side IIRC the S2 driveshaft can be fitted.
> - retighten the bolts from both  shaft flanges
> - Check if there's any play on the diff bearings and that it  turns easily
> - Fill the diff with some fresh oil. And check for leaks.
> -  Get it back under the car asap!! And while you're at it, throw in a
> powerflex  diff rubber aswell.
> 
> Enjoy some sideways actions!!
> 
> I'm not  responsible if there's a failure because someone used this method to
> swap his  diff. If you do this swap, use your common sence and check every
> step for  yourself.
> 
> Cheers  guys!