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Old 12-15-2007, 12:57 PM   #1
PERRIN_Ken
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Member#: 165212
Join Date: Nov 2007
Location: Hillsboro, OR
Vehicle:
2002 WRX
Blaze Yellow

Default DIY Perrin Rear Differential Cover Installation

While changing all of the fluids on PERRIN Project 15K we decided that we would take advantage of the situation and not only change the differential fluid but also add a little style and functionality to the rear end. Our rear diff cover is made from high strength, heat-treated cast aluminum. We've incorporated cooling fins into the design helping to reduce oil temps, in addition to looking good and cooling the oil better we've also increased the oil capacity more than 30% over stock. For a little more info click here.

Needed tools and gear:
1) New differential gasket (Can be purchased from any local Subaru dealer)
2) 1/2" drive wrench
3) 17mm wrench or socket
4) 14mm socket
5) Jack and jack stands

This is a very straight forward installation that can be done on either a commercial vehicle hoist or floor jack.



Step 1) Raise vehicle to desired height allowing you enough room to move freely. For this you will want to use jack stands to support the vehicle while removing and installing the differential cover. NEVER WORK ON A VEHICLE SUPPORTED ONLY BY A JACK.

Step 2) Once the vehicle is raised to the desired height you will want to use the 1/2": drive wrench to remove the lower "drain plug". You will also want to remove the upper "fill plug" at this time as well. Place these two plugs aside to be reinstalled later.

Step 3) Time to remove tension from the differential, this will allow you to remove the studs connecting the differential to the cross support. You'll need to get a floor jack for this next step. Placing the jack under the differential you'll want to raise the differential roughly .5".

Step 4) Using a 17mm socket remove the 17mm nuts securing the differential to the cross support. Remove the studs from the differential and the cross support by using the "Jam-Nut" method. (this is where you "jam" 2 17mm nuts together on one stud. Then you can remove the stud by unscrewing the nut closest to the differential). Repeat this process on the remaining stud. If this method doesn't work you'll have to use a stud-extracting tool.

Step 5) Once the two studs are removed from the differential and the cross support, its time to lower the differential. If needed you may want to remove or lower the exhaust system allowing yourself more working room. Because our vehicle had a differential skip plate we had to remove the exhaust. You now should see and have access to all 8 14mm bolts securing the differential cover to the differential. Using a 14mm socket remove the bolts. (NOTE: WHILE REMOVING THE DIFF COVER THERE WILL BE ADDITIONAL OIL THAT WILL BEGIN TO COME FROM THE BOTTOM OF THE DIFFERENTIAL). Once the cover is removed you'll want to wipe out as much excess oil from the differential as possible.

Step 6) Once everything is clean you can place THE NEW DIFFERENTIAL GASKET to the PERRIN differential cover. Using the 8 14mm bolts remove earlier loosely place the cover back into place. Starting at the top two bolts tighten the bolts to 21.7ft-lbs.

Step 7) Raise the differential back into place using the floor jack. Once the differential is in place (you'll be able to tell because the differential nut holes will line up with the cross support holes). With everything lined up you'll want to place and tighten the two bolts/nuts removed earlier to 52ft-lbs. Before doing this thread studs into differential cover until they are bottomed out.

Step 8) Reinstall the lower drain plug into the newly installed PERRIN differential cover. Tighten this drain plug using the ½" drive wrench to 36.2ft-lbs.

Step 9) Fill differential with proper high quality gear oil until oil starts to drip from the upper fill hole. Install the upper plug and tighten to 36.3ft-lbs.

Step 10) Lower vehicle and take it for a test drive. Check for oil leaks after the test drive.


Ken Jubb
Sales
PERRIN Performance***8482;
AIM: altaperrinsales4
1-503-693-1702 Ex. 113
[email protected]
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Last edited by PERRIN_Ken; 12-23-2007 at 12:29 AM.
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Old 12-16-2007, 08:43 PM   #2
Str8Gone
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Thats looks mean, now I just need to go out and get an STI rear diff
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Old 12-16-2007, 10:57 PM   #3
PERRIN_Ken
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Blaze Yellow

Default

Quote:
Originally Posted by Str8Gone View Post
Thats looks mean, now I just need to go out and get an STI rear diff
We did this application on our 2002 WRX. I also recommend that when you replace the diff cover you also install our P.S.P. I only say this because you have to go through half of the same steps for both.

Have a good one

Ken

Ken Jubb
Sales
PERRIN Performance***8482;
AIM: altaperrinsales4
1-503-693-1702 Ex. 113
[email protected]

Last edited by PERRIN_Ken; 12-23-2007 at 12:33 AM.
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Old 12-16-2007, 11:01 PM   #4
djerickd
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Clean on 19's

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Quote:
Originally Posted by Str8Gone View Post
Thats looks mean, now I just need to go out and get an STI rear diff
I too thought these were only for the STi...
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Old 12-17-2007, 07:19 PM   #5
BenMara
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Default

Quote:
Originally Posted by PERRIN_Ken View Post
I also recommend that when you replace the diff cover you also install our P.S.P. I only say this because you have to go through half of the same steps for both.
what Perrin product are you referring to ?? P.S.P.???
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Old 12-18-2007, 03:16 AM   #6
PERRIN_Ken
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2002 WRX
Blaze Yellow

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Quote:
Originally Posted by BenMara View Post
what Perrin product are you referring to ?? P.S.P.???

Nope we have a diff cover that works on the STI and one for the WRX. PSP I dont know what I was thinking I ment S.L.S. (Subframe Lockdown System). It is a really simple install. It helps firm up the rear end.

Sorry for the typo....

Ken

Ken Jubb
Sales

PERRIN Performance***8482;
AIM: altaperrinsales4
1-503-693-1702 Ex. 113
[email protected]

Last edited by PERRIN_Ken; 01-12-2008 at 12:09 PM.
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Old 01-10-2008, 11:57 AM   #7
PERRIN
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Default Coupon Code And Details Check It Out!

Quote:
Originally Posted by djerickd View Post
I too thought these were only for the STi...
The same cover won't work on both STi and WRX. The rear end is different. BUT we do offer both styles.

WRX Style Click HERE!

STi Style Click HERE!


Also as a special deal for our NASIOC friends, order direct form PERRIN either of the styles above and receive and addl. 15% off the purchase price!

During checkout use coupon code COOLDIFF (must be caps) for 15% off. Price good for 30 days!

Thanks again everyone!

[email protected]
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Old 01-29-2008, 12:03 PM   #8
kingmissil
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WR Blue

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ordered this and the lock down kit. Look forward to the install.
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Old 01-29-2008, 12:15 PM   #9
Crazykev
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331whp/331wtq

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Very nice cover. I swapped to an R180 and used your cover. Looks freakin' killer





Also made my own magnetic alum. plug from the factory magnet. Rivited and J B welded. It can't ever fall off and makes the diff look even more trick.

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Old 01-29-2008, 01:42 PM   #10
djerickd
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Clean on 19's

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nice plugs!
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Old 01-29-2008, 03:07 PM   #11
kingmissil
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that came out nice, excellent work.
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Old 01-29-2008, 05:43 PM   #12
PERRIN_Ken
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Looking good and I love the plugs

Ken

Ken Jubb
Sales
PERRIN Performance™
AIM: altaperrinsales4
1-503-693-1702 Ex. 113
[email protected]
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Old 01-29-2008, 09:08 PM   #13
scby rex
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aw, MPS 2.34 breaking in

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this isnt really related but could be. How do you tell the difference between the 06 sti r180 and the others from the outside? Mine just came in and I want ti be sure.
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Old 01-29-2008, 09:11 PM   #14
Crazykev
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331whp/331wtq

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You have to take off the cover and get the tooth count numbers off the ring gear and they should be a 3.54 ratio. Divide the larger number by the lower. I don't remember what the numbers are off hand.
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Old 01-29-2008, 09:17 PM   #15
scby rex
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aw, MPS 2.34 breaking in

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I dont know what you mean but divide the larger# by the smaller#, It should be 3.54, I just dont want to take it apart as if its wrong Ill be shipping it back. Are there any #s on the outside? Sorry jeff for mudding up your thread.
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Old 01-29-2008, 09:59 PM   #16
PERRIN
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acby rex: No muddy issues here! We like a nice interchange of information.

They covers are different sizes as well. The holes are different etc. Maybe we can get Ken to take a side by side, so you folks can see better.

Thanks again!

[email protected]
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Old 01-29-2008, 10:04 PM   #17
scby rex
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aw, MPS 2.34 breaking in

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ok I just put this in my thread, but I have a 06 sti rear diff and is has this on the bottom
ND1058
o2
56D
layed out like this on the bottom, Adam do you know if this is a 06 for sure and not a 05 or 07? Thanks.

Last edited by scby rex; 01-29-2008 at 10:07 PM. Reason: wrong person
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Old 01-29-2008, 10:17 PM   #18
Crazykev
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R160 and R180

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Old 01-29-2008, 10:24 PM   #19
scby rex
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aw, MPS 2.34 breaking in

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do all r180s have the 21 stamp on them like the r160 have the star?
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Old 01-29-2008, 11:01 PM   #20
Token-Negro
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Last edited by Token-Negro; 01-31-2008 at 12:44 PM.
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Old 01-29-2008, 11:03 PM   #21
scby rex
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nice^
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Old 01-29-2008, 11:16 PM   #22
Paranoid Fabrications
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yea, that green one is nice looking
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Old 01-29-2008, 11:17 PM   #23
modaddict
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yellow FTW!
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Old 01-30-2008, 12:55 AM   #24
Paranoid Fabrications
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Quote:
Originally Posted by modaddict View Post
yellow FTW!
no no no. Green FTW
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Old 01-30-2008, 07:35 AM   #25
Crazykev
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Thread size is 3/4" NPT and not 1/2" NPT sorry if I screwed anyone up

The plugs that I used were 3/4"" NPT incase anyone is interested.

Nice work on the painted ones guys. I was also going to use SS allen bolts on my cover, but decided to skip it. Looks good. I did do the SS bolts on my bearing caps . Almost all bolts under my hood are SS allen bolts. 90% are including all the bolts for the intake mani including the long 8mm ones that bolt it down to the head. All the ones that can be seen are SS allen.

Last edited by Crazykev; 02-01-2008 at 07:20 AM.
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