Welcome to the North American Subaru Impreza Owners Club Thursday December 25, 2014
Home Forums WikiNASIOC Products Store Modifications Upgrade Garage
NASIOC
Here you can view your subscribed threads, work with private messages and edit your profile and preferences Home Registration is free! Visit the NASIOC Store NASIOC Rules Search Find other members Frequently Asked Questions Calendar Archive NASIOC Upgrade Garage Logout
Go Back   NASIOC > NASIOC Technical > Transmission (AT/MT) & Driveline

Welcome to NASIOC - The world's largest online community for Subaru enthusiasts!
Welcome to the NASIOC.com Subaru forum.

You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, free of charge, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join our community today!

If you have any problems with the registration process or your account login, please contact us.
* Registered users of the site do not see these ads.
Reply
 
Thread Tools Display Modes
Old 04-07-2012, 07:46 PM   #1
talvai
Scooby Specialist
 
Member#: 136358
Join Date: Jan 2007
Chapter/Region: NESIC
Location: Newington, CT
Vehicle:
2006 WRX Limited
6mt/5x114/vf43/S204

Default Rear Diff Sensor Install Guide

So been asked by a couple members here to post on I am doing my install for rear diff sti temp sensor and light on the sti cluster. Going to post as I do things(sorry just don't have time to do everything in one shot). Way I do it is not the only way of doing it, just the way I decided was best. I will be as detailed as possible. However had a hard time taking pictures under the car since I only has a few inches of clearance. I did this install on a 06 WRX Limited. I am sure its the same for all 02-07 models.

If somebody knows where I can upload the pictures so I don't accidently remove them in the future that would be great too.

Give everybody idea on cost I spent $90-100 total for everything. I got entire rear harness and new sensor from a member here.

Items you need:
Rear diff temp sensor
Rear diff temp sensor pigtail tail
Ground bracket for rear diff
STi cluster



Here is the wiring diagram for it. You can see sensor has 2 cables. Only 1 of these cables are actually on the sensor. The other(ground) gets attached to a separate bracket mounted on the rear diff and grounded to the chassis. So doesn't matter where you decide to ground that cable. I personally have choosen a nut under steering dash that holds all the fuses and is mounted to the big round bar.

The cable from the sensor goes directly to the cluster pin. You say Talvai but it touches DCCD controller. Yes it does. This is because when light is on it locks the center diff to help cool the rear diff. However since I have DCCDPro controller I have to just override this. Of course if you wanted to you can tap on of the DCCD cables before cluster so it sends power to it and therefore locks the diff. I am perfectly fine locking the diff myself so I going around it.

I still need to pick up this bracket. Its called Stay-earth and part number is 11086AA022 its about $2-4 from dealership new. The sensor part number has a couple not sure the differences between them if any. 27043AA011, 27043AA012, 27043AA012. These sell for about $120 new from dealership.


Step 1 is easy. Install your rear diff temp sensor. My diff is from a JDM site so I didn't have a sensor already installed. Sensor goes on top bolt location.




Step 2. Prepare your pigtail if you have whole harness. This harness is called fuel cord. Partnumber is 81803FE052. Don't know cost of it, but sure its not cheap. All you really need is the rear diff connections. So I detaped the entire harness, removed all hard plastic pieces and cut the harness. I did not want to replace my entire harness as 90% of these connections are just a pain to reach as they are above the fuel tank.



Step 3. Now that everything is detaped you removed the plastic that surround the other cables I know cut my harness so that I only had the 2 connectors I needed. If you cut this harness all the way at the end you will have enough cable to reach the backseats. From that point on you need to solder cables together to extend it.

That being said I didn't want this harness to go to waste so saving cables for future project and all the plastic I removed I wrapped around the rear diff pigtail and then taped it all with electrical tape. I did this for a few reasons. One reason was weather as I know feel comfortable that no water/snow/mud will reach the cables themselves. Other reason was so when I wiring it didn't have to worry about wires getting cut from touching metal.


Above is a picture of the rear diff harness before electrical tape and plastic pieces. Note the 2 connectors for the sensor and bracket.


Step 4: Wire cable from rear diff to inside the car. How you do this up to you. I decided I wanted to route it on driver side as its closer to cluster and I found a spot to go inside. I also choose this method because it hides the cable very well and looks almost OEM like. As you can see harness is in on sensor(other cable is tucked up top). I put the clip on the crossmember just like STi and then ran it above the rear crossmember.

Above the crossmember I clear all axles, swaybars, lateral links, etc. I then went through little openning at the end of the crossmember right by fuel tank. Sorry don't have pics as they came out all blurry. Their is a little hole on a plastic surrounding the fuel tank. I zipped tied the wire there and continue to run it along side ABS line. From there I noticed 3 hardlines however the rubber piece had a spot for a 4th that was empty. So figured perfect spot to run cable inside.


This is where I ran the cable inside. This is where backseat would be on the driver side. Note the bar that goes across, the 3 hardlines and the ABS cable. That rubber piece had a hole not being used. So poke a little hole in it and ran the cable. Now that the cable is inside, I soldered cable to make it longer to reach the front of the car and you can run it along the door sills, hiding it the entire time.
talvai is offline   Reply With Quote
Old 04-07-2012, 07:47 PM   #2
talvai
Scooby Specialist
 
Member#: 136358
Join Date: Jan 2007
Chapter/Region: NESIC
Location: Newington, CT
Vehicle:
2006 WRX Limited
6mt/5x114/vf43/S204

Default


Where I circled in red is where I grounded the cable. You can ground it anywhere I felt this made all my cable ends in one place and easy to access after. This this where the big round bar behind the dash is.


This is the center harness of the 3 behind the cluster. The one I have circled is B4 which is for the rear diff sensor. The one above my finger is for IC Spray light.


I also picked up the Stay Earth and attached it to the rear diff. This bracket goes to one of the bolts holding the cover on the rear diff. I then attached both cables. (Sensor and ground)


Everything is down. When you turn the key to On(no engine). You will see the rear diff temp light on.


When engine is turned on the light goes off.

Thats all it is. Hopefully this will be useful to somebody.

Last edited by talvai; 04-14-2012 at 06:18 PM.
talvai is offline   Reply With Quote
Old 04-07-2012, 07:47 PM   #3
talvai
Scooby Specialist
 
Member#: 136358
Join Date: Jan 2007
Chapter/Region: NESIC
Location: Newington, CT
Vehicle:
2006 WRX Limited
6mt/5x114/vf43/S204

Default

Reserved for when I continue install 2
talvai is offline   Reply With Quote
Old 04-14-2012, 06:19 PM   #4
talvai
Scooby Specialist
 
Member#: 136358
Join Date: Jan 2007
Chapter/Region: NESIC
Location: Newington, CT
Vehicle:
2006 WRX Limited
6mt/5x114/vf43/S204

Default

Guide finished bump. Hopefully somebody finds this useful.
talvai is offline   Reply With Quote
Old 04-15-2012, 02:56 PM   #5
DCCDPro
Former Vendor
 
Member#: 227549
Join Date: Oct 2009
Location: Guelph, Ontario
Default

Nice write up! I think it will help quite a few people.
DCCDPro is offline   Reply With Quote
Old 06-15-2012, 05:31 PM   #6
Rabid_Machina
Scooby Specialist
 
Member#: 167278
Join Date: Dec 2007
Chapter/Region: NWIC
Location: Olympia
Vehicle:
2004 WRX
PSM

Default

subscribed
Rabid_Machina is offline   Reply With Quote
Old 06-18-2012, 10:09 AM   #7
Samurai Jack
Scooby Specialist
 
Member#: 21145
Join Date: Jul 2002
Chapter/Region: NESIC
Location: Not in my own time
Vehicle:
2002 Enemy of Aku

Default

Nice write-up. If I ever decide to add the temp sensor, this will make it a lot easier.
Samurai Jack is offline   Reply With Quote
Old 07-04-2012, 06:08 AM   #8
lancelucas
Scooby Specialist
 
Member#: 124282
Join Date: Aug 2006
Chapter/Region: NWIC
Location: 30000 ft
Vehicle:
04 WRX Wagon PSM
13 STI Sedan SWP

Default

Many thanks for this, I got my sensor hooked up and working correctly tonight! For search reference, I added a working rear diff temp sensor to my 04 WRX Wagon with 04 STI Cluster.

I found a harness from an 06 STi on eBay for $40 shipped. I simply searched for "sti fuel tank harness" and a few popped up. Rather than undo the entire harness I clipped the pigtail where it meets the next big junction (where the loom ends in your pic) and soldered/heatshrinked on some long extension 18ga wires with 1/4" wire loom to cover it with a few feet to spare after entering the cabin. I used the same grommet as the aforementioned fuel tank harness (pass side under the seat) as it had quite a bit of free space. I'll try to take a picture of the under-car routing next time it's in the air, it's late and I am tired.

I then crossed to the driver's side and I attached the ground side at a rear seat bolt. The cluster wire then went forwards up the door sill area like you did and into the cluster area. I had a spare dash harness so I stole the pins out and added one to B4 of my harness. A few more solder and heatshrink sessions, reassemble and I'm in business with a working cluster light! Thanks again for the info on this

Next up is DCCDPro with working cluster illumination and outside temperature sensor
lancelucas is online now   Reply With Quote
Old 07-04-2012, 08:59 AM   #9
talvai
Scooby Specialist
 
Member#: 136358
Join Date: Jan 2007
Chapter/Region: NESIC
Location: Newington, CT
Vehicle:
2006 WRX Limited
6mt/5x114/vf43/S204

Default

Quote:
Originally Posted by lancelucas View Post
Many thanks for this, I got my sensor hooked up and working correctly tonight! For search reference, I added a working rear diff temp sensor to my 04 WRX Wagon with 04 STI Cluster.

I found a harness from an 06 STi on eBay for $40 shipped. I simply searched for "sti fuel tank harness" and a few popped up. Rather than undo the entire harness I clipped the pigtail where it meets the next big junction (where the loom ends in your pic) and soldered/heatshrinked on some long extension 18ga wires with 1/4" wire loom to cover it with a few feet to spare after entering the cabin. I used the same grommet as the aforementioned fuel tank harness (pass side under the seat) as it had quite a bit of free space. I'll try to take a picture of the under-car routing next time it's in the air, it's late and I am tired.

I then crossed to the driver's side and I attached the ground side at a rear seat bolt. The cluster wire then went forwards up the door sill area like you did and into the cluster area. I had a spare dash harness so I stole the pins out and added one to B4 of my harness. A few more solder and heatshrink sessions, reassemble and I'm in business with a working cluster light! Thanks again for the info on this

Next up is DCCDPro with working cluster illumination and outside temperature sensor

Glad this has been helping people out. Yea way I did it is by far not the only way but if you copy it will work or just pull idea here or there. With DCCDPro you get get cluster lights and if you really want(I didn't do it) you can lock the diff automatically when rear diff light comes on just like OEM. Personally I would just lock it myself if it came to that, but option out there if somebody really wants to do it.

I wish I could take better pics to show you how cabling is route under the car but since I did this on jack stands and I have only a long lens for my slr camera its hard to do.
talvai is offline   Reply With Quote
Old 08-12-2012, 08:14 PM   #10
spongerrich
Scooby Newbie
 
Member#: 214736
Join Date: Jun 2009
Chapter/Region: SCIC
Location: Oceanside, CA
Vehicle:
2005 WRX wagon WRB
Cobb Stage 2 OTS

Default

Just installed an STI cluster in my 05 WRX wagon and interested in doing this. I have the stock 5-speed (for now) so no DCCD. Will this still work?
spongerrich is offline   Reply With Quote
Old 08-13-2012, 09:20 AM   #11
talvai
Scooby Specialist
 
Member#: 136358
Join Date: Jan 2007
Chapter/Region: NESIC
Location: Newington, CT
Vehicle:
2006 WRX Limited
6mt/5x114/vf43/S204

Default

Quote:
Originally Posted by spongerrich View Post
Just installed an STI cluster in my 05 WRX wagon and interested in doing this. I have the stock 5-speed (for now) so no DCCD. Will this still work?
As longs as you have sti cluster and sensor this will work. Keep in mind though even if the sensor fits the R160 its designed for R180. So when light comes on its calibrated for R180 heat threshold.
talvai is offline   Reply With Quote
Old 08-30-2012, 01:02 PM   #12
Vlad
Scooby Guru
 
Member#: 46135
Join Date: Oct 2003
Chapter/Region: Tri-State
Location: NY
Vehicle:
02 WRX
Sti V9 Spec C

Default

So, guys with the sensor and the R160, do you see the light in the dash coming on sometimes?
Not talking about autocross, rather about fast driving on a hot day, by example.

Edit: So after searching everywhere, as far as the R180, the only one instance of legitimate overheating causing the light to come on was one person stuck in snow, trying for 20 minutes to rock back and forth, this was not even on Nasioc.
Nobody posted this happening hot, even at the track, autocross, anything.

There have been numerous instances of the light coming on, but this is because the sensor needs a good path to ground. And the path between the diff cover and the body of the car, as far as grounding is concerned, can be sketchy.

Now that I have the sensor on the R160, I am curious to see if it will ever come on. I'll probably add dedicated grounding on the diff cover, just to make sure..

Last edited by Vlad; 10-01-2012 at 02:25 PM.
Vlad is offline   Reply With Quote
Old 09-20-2012, 04:41 PM   #13
Vlad
Scooby Guru
 
Member#: 46135
Join Date: Oct 2003
Chapter/Region: Tri-State
Location: NY
Vehicle:
02 WRX
Sti V9 Spec C

Default

The other part number for sensor is an early one. That sensor has only one wire coming out and needs a slimmer connector to fit. It grounds directly to the housing it threads to.
Vlad is offline   Reply With Quote
Old 09-28-2012, 08:18 AM   #14
Vlad
Scooby Guru
 
Member#: 46135
Join Date: Oct 2003
Chapter/Region: Tri-State
Location: NY
Vehicle:
02 WRX
Sti V9 Spec C

Default

So, I followed this guide and have installed the sensor. I did not install that stay/ground bracket and immediately, I started to have ground continuity problems.
The stay bracket looks good, seems stainless, I think I'll order it and make sure the diff is nicely grounded.

Can't wait to do donuts in snow again, and see if I really heat up that R160

Edit: I Grounded this to the rear chassis grounding point, inside the trunk, by the trunk latch, works nicely.

Last edited by Vlad; 10-01-2012 at 02:26 PM.
Vlad is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
WTB : S203/204 Rear Damper & rear diff sensor harness talvai Private 'Wanted' Classifieds 0 01-22-2012 07:13 PM
Anyone have a spare rear diff sensor? Undepelo Mid Atlantic Impreza Club -- MAIC 0 07-27-2007 10:41 PM
WTB: rear diff sensor silver-sti Private 'Wanted' Classifieds 0 07-06-2007 01:29 AM
IS rear diff sensor needed? John2.5RS Subaru Conversions 1 07-12-2006 03:52 PM
Rear Diff Sensor qingshan Transmission (AT/MT) & Driveline 3 01-12-2006 12:22 AM


All times are GMT -4. The time now is 07:33 PM.


Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Powered by Searchlight © 2014 Axivo Inc.
Copyright ©1999 - 2014, North American Subaru Impreza Owners Club, Inc.