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Old 03-27-2013, 12:39 PM   #1
Faster_Gun
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2004 WRX WGN 348whp
1977 GMC Brodozer

Default Solved: R180, custom axles, and a clicking/popping rear

Gents,

I'm very confused. I've got a 04 WRX wagon swapped with a 05 STI 6 speed and R180. I built WRX/STi axles so I can keep my WRX hubs.

Upon running the car in the air the car makes a clicking noise from the rear and you can feel it in the halfshafts. Dropping it down it drove fine until it had to turn, at which point it feels like it popped out an axle.

Back in the air, the diff is moving side to side, one axle is showing a compressed boot, the other is extended, like my diff isn't centered?!

I'm taking any ideas at this point.

Additional info: The axles used to build mine are the stock 04 wrx axles pulled from my wagon and 04 STi axles. I'm on Epic Engineering springs.

Best Regards,
Mike
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Last edited by Faster_Gun; 10-10-2013 at 07:52 AM.
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Old 03-27-2013, 02:52 PM   #2
Faster_Gun
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More info, the dealership doesn't think its possible to get a rear diff install wrong, thus eliminating my thought that the rear diff was too far too one side. In addition to that I had the distance from the hub to the diff measured on both sides. The distance is the same.

According to the dealership the rear axles on the wagon wrx and sedan wrx are different part numbers (implying different lengths?)
According to DSS the rear axles are the same on the rears of the WRXs (They say their WRX > R180 diff axles will work in both applications)
According to the dealership the left and right axles on everything have different part numbers (implying different lengths (or masses for harmonics?!)?)

I'm at a complete loss for my next step.

It should also be noted, I have no idea if this six speed/r180 is good. Its not making any funny noises and its behaving the exact same as a car with an axle popped out. Dealership says they think its okay.

Help!
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Old 03-27-2013, 03:16 PM   #3
Hondaslayer
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99% Sure that the wagon axles are shorter. I know for a fact that the fronts are and I am fairly sure the rears are as well. I would measure the length of your shaft vs sedan shafts and go from there.

PS: Ask Jeff if he has helped any sheep over fences lately.


-Ben
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Old 03-27-2013, 03:50 PM   #4
Faster_Gun
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Default

Thanks for the reply Ben.

Im not sure what all this sheep business is, but ill let him know you asked.

That's the thing, I used my existing axles from my car, WRX wagon axles. I just removed the R160 diff side outer spline and put on the R180 side from the same year axle (same bearing count). In theory all I should have done is increased the male diff side length, allowing the axles to snap into the circlip in the diff.

Is my logic flawed somewhere here?
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Old 03-27-2013, 03:52 PM   #5
mpalm
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*edit* Oohh look you just answered that...
So you used the WRX race with 6 bearings? I think you need custom ones in order for this to work

Last edited by mpalm; 03-27-2013 at 04:07 PM.
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Old 03-27-2013, 04:13 PM   #6
RossLH
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A friend of mine in MD recently had the same problem with the rear axles popping out of his 6-speed/R180 swap. I'll see what he has to say.

EDIT: By the sound of it, all he did was make sure the circlip opening was facing up, seated the axles, and hammered the axles in until they seated properly.
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Old 03-27-2013, 04:43 PM   #7
Faster_Gun
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Quote:
Originally Posted by mpalm View Post
*edit* Oohh look you just answered that...
So you used the WRX race with 6 bearings? I think you need custom ones in order for this to work
I thought the same, but I cant figure out what a custom race would do for me. There is a tiny bit of torsional play in one of the shafts, but other then that they feel like an OEM piece.

Quote:
Originally Posted by RossLH View Post
A friend of mine in MD recently had the same problem with the rear axles popping out of his 6-speed/R180 swap. I'll see what he has to say.

EDIT: By the sound of it, all he did was make sure the circlip opening was facing up, seated the axles, and hammered the axles in until they seated properly.
It looks like I may have found the reason for compression and extension in my axles.

This states the WRX axles are different from side to side. Ill have to switch them around and see what happens. After flipping them around, ill give this a try.

Thanks for the replies guys, looks like I have some direction to go now, rather then sitting on my ass scratching my head.

Ill be in touch when I still cant drive.
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Old 03-27-2013, 04:49 PM   #8
Hondaslayer
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More important than left to right is that the axle shafts are 10mm shorter sedan to wagon.

I think you need a longer shaft (that's what she said!)
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Old 03-27-2013, 04:52 PM   #9
mpalm
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No but he is using wagon shafts on a wagon, so that should be fine.
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Old 03-27-2013, 08:43 PM   #10
Hondaslayer
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Damnit, I forgot he has a wagon
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Old 03-28-2013, 10:57 AM   #11
Faster_Gun
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Default

Okay, the word back from Hodges is that after they swapped axles only 3 wheels spin. Now they're assuming bad rear diff. I'm going to go in and try hammering them in, because to me it sounds like they got 1 seated, and one halfway in.
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Old 03-28-2013, 12:43 PM   #12
mpalm
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Even if it was halfway in it should still spin though right? As long as the splines are on. It's not like a dealership to mess something like that up either...

assuming it's a rear wheel not spinning?
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Old 04-01-2013, 10:58 AM   #13
Faster_Gun
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2004 WRX WGN 348whp
1977 GMC Brodozer

Default

Yeah, I would expect it to drive in the air and maybe drive on the ground poorly. Anyone have a spare 3.9 R180 they want to lend me?
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Old 04-18-2013, 06:28 AM   #14
Faster_Gun
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1977 GMC Brodozer

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The car is on the way back from Hodges on Friday. Suberdave races are in the mail. We'll see if this is the magic bullet soon. My suspicion is no.
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Old 10-10-2013, 07:51 AM   #15
Faster_Gun
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2004 WRX WGN 348whp
1977 GMC Brodozer

Default

Just as a conclusion to this thread:

Hodges blew up one of my ghetto axles. The blown axle was causing the popping and clicking. I dragged the car home and replaced the axle with a SuberDave inner race hybird axle and made it out of my neighborhood. Upon exiting my neighborhood I entered boost and snapped the other axle. Dragged the car back home and discovered I had shattered the bearing carrier on the non-suberdave axle. I cannibalized a spare STI axle I had for its bearing carrier, reassembled my now suberdave axle, and ive been driving on it ever since. (~4000miles)

Lessons learned:
They don't just sell the bearing carriers/bearing cages anywhere
Make sure you keep your axles on the proper sides
Wagon v Sedan axles are different
Inner races that almost fit perfect, don't fit perfect at all. The slop was enough to blow up an bearing carrier
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