Center Diff Washer mod for 20/80 TBR

[Poopie]

This is for a prefacelift 01A transmission with a 2 piece center diff. I highly recommend air tools for a lot of the assembly. Gotta have your basics tools too. I got the washers complements of kompressed. He was very helpful on tips with the installation. Wouldn't be possible with out him.

First start off by putting the car on 4 jack stands to make the car sit level. lay some news paper or an old towel down to keep the floor clean while you drain the tranny fluid. Use a 17mm allen socket to open the fill plug. Then use the tranny drain plug tool and remove the tranny plug and drain the fluid into a oil catch container.

After the fluid is drained, put the drain plug back in. Then remove the driveshaft heat shield. It is held on by 4 10mm nuts

Then take the drive shaft off from the center differential. its 6 bolts. Use and impact gun if you don't want to keep getting up from under your car to release the hand brake to rotate the shaft. Slide the driveshaft away and put a bag or a rubber glove over the greased ends.

Then start pulling the center diff out. Its like 7 t45 torx bolts. Unless your car is on a lift, you don't have much room to crack the bolts off. Impact gun and air tools were a savior. a few extensions and u joints made it cake. After that place a towel underneath incase all the tranny fluid did not drain out. use a rubber mallet to hammer the diff off the output spline of the tranny.

make yourself a clean area to work with to start dissassembling the diff.

You first need to remove the torsen. There is a clip holding in a rubber plug. Remove the clip and insert a 8mm bolt into the thread part in the middle of the plug. This gives you something to grab to pull it out. Then use a wooden dowel to punch the diff out.

You will get something that looks like this...



mark the cap and the main body so you assemble it in the same position. I used a white out pen.

Then is an impact gun and a 8mm allen socket to remove the 3 bolts. i used an impact gun because i did not want to mount the diff in a vice.



Once the cap is off there is a washer on the main center gear. Place that somewhere safe. Then mark the main gear to make timing the diff easier.



Then start marking the gears on the side.



This is why you need to properly time the gears. The pic is bad but there are angles cut into the vertical gears so they don't mash into the spiral teeth on the two center gears. Just yse a white out pen, mark a tooth and then mark the body.



These needle bearings are what you are replacing. The thrust washers are the same demensions. You will need to get custom precision ones ground out at a machine shop.





replace the bearings and use some lube in between the washers.





now reassemble. Match up the gears to the marks you made earlier



you should be able to spin it by hand with out any crunching noises.

No just reverse for assembly.

[k0mpresd]

thanks for the kind words..and you only called once haha...i was surprised

you like it ? ..super excited i was able to help you w/ this

[bassed]

And the results when exiting or entering? Point and shoot? A$$ happy late apex fun?

[Poopie]

My tires are too sticky =( breaking grip has never been so hard. Yokohama prada spec 2's for the loss. I got my ass end once and it was pretty fun. I need to find some good roads.

[audiFUEGO]

Good Work!

I vote: STICKY

[k0mpresd]

My tires are too sticky =( breaking grip has never been so hard. Yokohama prada spec 2's for the loss. I got my ass end once and it was pretty fun. I need to find some good roads.

my tires are totally shot so its a little easier for me

but the drivetrain mechanically and electronically (edl) i think both do a good job of sorting everything out once you are sideways

just wait until it rains though ;)

i would like to add, you mentioned machined and teflon coated. the teflon washers are what gets replaced in the 1 piece diff. there is no teflon on your washers nor any on the ones in my diff. not anymore anyways haha ;)

awesome post btw

[317ssayzarc]

cant wait to get my washers so i can do this... big ups poops

[UCFQuattroguy]

just a tip...there are already timing marks on the gears. It'll either be an "I" "E", "T" or "B" from what I've seen and will be between the outer teeth. As far as how to orient them, Torsen's website has a blueprint with timing specs.

As far as driving, if you're driving "correct" lines and not trying to be dramatic and "hey look at me", the car will still slightly understeer at the limit (BIG variable being your suspension setup), but you'll be exiting the corner a bit quicker than before. When you are trying to be all dramatic about it...an exaggerated late apex as the boost comes on during a 1st gear U-Turn *WILL* get the back of the car out on you...at the same time you'll be burning up the inside-rear tire if you're still running the stock open diff in the rear. This open diff will really kill much of the tail-happiness we're all after (once it spins, load is taken off the rear, sending torque forward).

[Poopie]

my tires are totally shot so its a little easier for me

but the drivetrain mechanically and electronically (edl) i think both do a good job of sorting everything out once you are sideways

just wait until it rains though ;)

i would like to add, you mentioned machined and teflon coated. the teflon washers are what gets replaced in the 1 piece diff. there is no teflon on your washers nor any on the ones in my diff. not anymore anyways haha ;)

awesome post btw

edited. no rain for the next couple days though =(

I'm working on front bumper. I hit an ice chunk a few weeks back and destroyed my bumper. Got to look good for the blowneuroz gtg. Also adding a curpa r splitter.

[Poopie]

just a tip...there are already timing marks on the gears. It'll either be an "I" "E", "T" or "B" from what I've seen and will be between the outer teeth. As far as how to orient them, Torsen's website has a blueprint with timing specs.

Yeah i saw that. Those were gonna be my back up method to allign the gears. I think marking them is much easier.

[k0mpresd]

Yeah i saw that. Those were gonna be my back up method to allign the gears. I think marking them is much easier.

seems way easier...no guessing or going "uh..did i do that right?"

[manufan]

Who needs washers?

[UCFQuattroguy]

seems way easier...no guessing or going "uh..did i do that right?"

I've found that it'll either go together, or it won't. Haven't really done one to where I'd have to put it 100% together before I'd know if it was done right. When the timing has been off, I wouldn't even be able to slide the axel in place on one of the upper gears.

[k0mpresd]

i feel better knowing that

because when i did my 1 piece and the 01e diff, i left a set of the side gears in the housing each time

both times during reassembly everything seemed to only fit one way

[soupie69uk]

Nice write up.

Did you take any pics taking the torsen out the car?

[k0mpresd]

getting the torsen housing off the gearbox is pretty easy

just disconnect and move the driveshaft out of the way and then the bolts around the housing. and then its off

[soupie69uk]

Which drive shaft? Or is it the propshaft?

[k0mpresd]

center driveshaft..from the back of the gearbox to the rear differential

you will need to take out the 2 bolts that hold the carrier bearing to the body of the car as well

[soupie69uk]

Ah I get you cheers lads.

I have ordered my washers so should get them soon.

[k0mpresd]

let me know when you get the pins

also, if you have any more questions feel free to shoot me a pm

did you find a machine shop to do the work yet?

[Audii-Dudii]

I've found that it'll either go together, or it won't. Haven't really done one to where I'd have to put it 100% together before I'd know if it was done right. When the timing has been off, I wouldn't even be able to slide the axel in place on one of the upper gears.

FWIW, I'm not sure exactly what I did, but the first time I reassembled mine, it turned but only very roughly, which was clearly wrong. It took me a few more attempts to get it timed properly, but basically, you're correct: If the gears are not aligned correctly, you'll know it immediately.

[soupie69uk]

let me know when you get the pins

also, if you have any more questions feel free to shoot me a pm

did you find a machine shop to do the work yet?

Yeah I will let you know when they land mate.

My mate who has the workshop I use knows a machine shop that hopefully will do the washers for me. If not I will search about.

[k0mpresd]

ok. cool. good luck with your project

cheers

[ModifiedA4]

great post!

[Poopie]

Thanks! Sorry for the crappy pics. People should donate to my camera fund!

I guess this should be moved to the DIY section

[soupie69uk]

Hey folks I was looking at this diagram and it says there are two washers at the top?

http://torsen.com/fsae/012000_washer.htm

Do the metal washers I am getting made up replace both of these?

Are the two washers I need to get made up need to be the same size? Its just the site says they are different?

I have pm'd u this Kompresd

[Poopie]

yeah there are two washers. just replace the bearings. the new washer should be pretty much the same dimensions and the exact same thickness if you measure it with a micrometer. I think its like .077" thick...and the other washer that is already in the assembly is .100" thick.

[k0mpresd]

his 1 piece has a different set up than your diff poopie. no bearings in his

i replied to your pm btw

[andyrew]

Who needs washers?

I need washers!!!

[manufan]

PM kOmpresed, he'll give you the details.

[Casablanca2.8Q]

Who needs washers?

i do i do!

[-03 tq]

Is this true 4:1 mod or 3:1 ? Why doesnt JHM mod 2 piece torsens?

[A4Rob]

Is this true 4:1 mod or 3:1 ? Why doesnt JHM mod 2 piece torsens?

4:1 I did mine last winter. It is awesome! No idea why JHM doesn't do it.

[tyroneshoelaces]

Does anyone have any tips on getting the diff out of the housing? I pulled the snap ring and plug but I'll be damned if I can get the diff to come out of the housing. I can't really get a straight shot on it to tap it out if that is what needs done.

[k0mpresd]

you dont need a straight shot. i just used a piece of wood at an angle and tapped it out.

[Scotty@Advanced]

I've done 2 pieces diffs.

[tyroneshoelaces]

you dont need a straight shot. i just used a piece of wood at an angle and tapped it out.

Did it just slide out and leave the splined shaft in the housing that connects to driveshaft?

Edit: Just got it apart, had to slide that shaft out to hit it from the end.

[catbed]

Just a tip for others, I held the case of the diff that mates to the output shaft, then hit the housing around the diff with a rubber mallet. Worked like a charm.

I really love this mod. Went out in the rain yesterday and slide the rear out pretty nice. Can't wait for snow

[2stroke]

Is this a mod that make the Quattro system distribute the force 40 % Front and 60 % Rear instead of the OEM set upp 50 % Front and 50 % Rear ?
Or ?

I can not see the picures above, why ?

My B5 Quattro is made in September 1999 and have a 5-speed manual gearbox.
How do I know if the above mod can be done on my gearbox ?

[k0mpresd]

lol. did you not notice the 20/80 part? and its not 50/50. the stock set up will do up to 33/60.