Any BTDT on DIfferential [was Quaife diff in early coupe?]

[Ben Swann]

OK I'm getting into this job armed with dial indicator, etc. Shims and seals
on order.  Transmission is  5-speed 093 for an '83 GT Coupe receiving a
Quaife Limited slip differential.

The Bentley for 4000Coupe and Q Sec 35.33 in picture says "Differential can
be removed without removing gear carrier disassembling/assembling" but I
just dont see how.  So before I proceed any further I'd appreciate any
advice toward swapping in the Quaife differential.  Quaife came with no
instructions whatsoever.  I have the final drive cover off and the pinion
gear and main shaft are blocking the removal of the diferntial/ring gear
assembly.

Questions:

Should I at this point break open trans between the Final Drive housing and
gear carrier?  Will the pinion gear just slid out as well as the Main shaft
without difficulty on dissasemly/reassembly?  Do I need to be concerned with
exact mating position ( tooth-tooth) of pinion with respect to ring gear?

Despite some of the measuring tools on hand, I'm not finding it
straight-forward to do some of the precise measurements that are suggesed by
using special VW tools.   Will my best method of reassembling just be to
find the best combination of shims that  make the least amount of lash and
lateral movement of the differential yet allow the gears to mate and turn
without binding?

What exactly is meant by "preload"?

Is this swap more or less a matter of removing the factory differential and
unbolting and pressing off the ring gear and pressing it onto the Quaife
Diff and bolting it together - then reinstalling as taken apart using the
biggest shims that allow things to turn freely, but not exhibit "slop"?

Should I for the most part just make sure the diferential and ring gear are
assembled so that they are the same physical dimensions as the assembly I am
taking out?  I  took a measurement similar to that shown in sec. 39.29, and
there was about .032" lateral play on both sides.  I think that this may
have been too much, or should I duplicate this what appeared to me to be
slop from a well worn in transmission, or tighten up on this so the flanges
can't be pulled in and out so much/that is very little lateral movement?

Seems I don't have the type of dial indicator setup that can take the
angular measurement shown in 39.26 - 39.28, but I can do like in 39.29.  How
then do I get to doing the suggested measurements as shown in 39.24 to get
the exact shim sizes S1, S2, and S3.  Should I worry about S3, as I don't
see any reason to open the case there except for need to install a different
shim.

I'd appreciate helpful advice and suggestions to clarify, especially since
it seems I don't necessrily have all the specialized tools required, or
maybe I do: have caliper, micrometer, feeler guages, and borrowed a dial
indicator as well as bought one from Sears, but not taken out of the package
yet.

TIA

Ben

[----- Original Message ----- 
From: "CS_Rally" <cs at csrally.com>
To: "Ben Swann" <benswann at comcast.net>; <quattro at audifans.com>
Cc: "Ben Swann" <benswann at comcast.net>
Sent: Wednesday, June 02, 2004 12:24 PM
Subject: Re: Quaife diff in early coupe?


> Ben,
>
> Just install the new diff shouldn't be a big problem as long as you are
very careful and follow the book procedures. The transmission itself is
another story.
> Things to make sure while doing it (most common sense):
> 1. Replace all the seals and bearings you are dealing with during the
process. You know that this is a cheap insurance.
> 2. Have some spare shimms on hand.
> 3. The book says to measure couple of times the position of the diff
fromdifferent angles. This is the key, if the measurements aren't on the
specs you'll have problems. Measure them several times and couple more. When
I get to a point like this I normally call a day after being satisfied with
the numbers, go sleep and measure again next day, but this is me.
> 4. Buy new bolts for the crown.
>
> WARNING!!!
>
> This is a messy job, like you don't know that either.
>
> Later and good luck,
>
> Carlos.
> ----- Original Message ----- 
> From: "Ben Swann" <benswann at comcast.net>
> To: <quattro at audifans.com>
> Cc: "Ben Swann" <benswann at comcast.net>
> Sent: Wednesday, June 02, 2004 10:29 AM
> Subject: Quaife diff in early coupe?
>
> As I am doing an MC conversion in an '83 GT COUPE(non-Quattro)  for
someone,
> I was asked if it made sense to install an LSD eg. Quafe differential.  It
> does seem to make sense, and now would seem to be the time to do it.
<snip>
> Cheers!
>
> Ben]