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Old 06-26-2008, 09:19 PM   #1
reddevil
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Default Who wants a video on swapping a front diff?

I am swapping a 4.44 front diff into a tranny for a rally car. Who wants a video how to?

I forgot to add this video will be SUPER handy if you crack a gear and have a donor tranny of ANY year (5mt that is). I will show how to swap out the gear sets. So all of you 02 WRX owners can possibly fix your trannies when you break them.


1st of course you need a donor tranny of course. I have purchased a few of them from salvage guys when the case is damaged.

As far as I can tell, all the 5mt gear sets can be swapped from case to case from 1990 to 2007, no crappola. But no guaranties either. But I have swapped quite a few gearsets from one year tranny to another.

There are two caveats though. 1st you will need the correct center diff if the gearset is newer, but you can use an older gearset in a new center diff. This is due to the way the 5th gear is setup.

The other is you need to use the correct pinion shaft. So you would not be able to just lift the gears out of a 4.11 and install them in a 3.9. You would need to swap the shaft. I cover this.
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Last edited by reddevil; 06-27-2008 at 11:49 PM.
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Old 06-26-2008, 10:08 PM   #2
RonJitsu
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Who doesnt want a video how to. Post it up!!
I'll come in handy for when I destroy mine.
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Old 06-27-2008, 02:31 AM   #3
ballitch
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Doug, definately show us this. I will probably never do it, but if I knew I had a video to guide me through it, I just might....


~Josh~
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Old 06-27-2008, 06:34 AM   #4
Unabomber
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That would be nice, but I'm afraid you'd convince someone without the requisite skill to think they could mimic your actions into failure. Maybe I'm too cautious, but I've been told that a front diff is a pro only action by several tranny techs.
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Old 06-27-2008, 07:47 AM   #5
talvai
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I agree if you showed how to remove the rear diff then I have no problem but changing the front diff is no small job. However I would love to see a video just to learn. Getting that extra bit of knowledge never hurt anybody
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Old 06-27-2008, 01:32 PM   #6
frdawg
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id like to see it,, i'm having the 4.444 conversion done at a shop, but it would be interesting to see how its done
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Old 06-27-2008, 03:36 PM   #7
wrxjrk
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Me Too.
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Old 06-27-2008, 06:33 PM   #8
Tim Sanderson
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If you don't have the correct tools then pleae don't bother. If you do have the correct tools then by all means please do.
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Old 06-27-2008, 06:43 PM   #9
axelthrasher
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+1 for video. I'd love to see how this might be done.
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Old 06-27-2008, 11:27 PM   #10
reddevil
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Quote:
Originally Posted by Tim Sanderson View Post
If you don't have the correct tools then pleae don't bother. If you do have the correct tools then by all means please do.

Correct tools include

12 mm socket and wrench
14mm socket and wrench
27mm (1 1/16th") socket and impact gun

cold chisel and hammer

Really not that much needed.

And there is a trick up my sleeve to make it fairly painless... You use the donor shims that almost always come with the pinion shaft. So you do not have to worry about setting lash. I have done 7(?) trannies now and none have failed (except for that cursed one , had nothing to do with me )

Really, swapping out the front diff, or replacing the ring gear, is pretty damn easy. Exspecially compared to actually doing a gear repair. That is a whole nuther ball of wax.


The "chapters" will be...

1 - removing the center diff
2 - removing the bolts that hold the tranny case together
3 - opening the tranny case and viewing the innards.
4 - removing the 3 main parts, input shaft and gears, output (pinion) shaft and gears, removing the front diff.
5 - swapping the 4.11 pinion shaft for the 4.44 pinion shaft.
6 - showing how to replace the spider gear if needed
7 - reinstalling the 3 main parts
8 - putting case back together
9- reinstalling the center diff, which is often the most frustrating part of the whole ordeal.

10 - done.
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Old 06-27-2008, 11:49 PM   #11
reddevil
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Default

I forgot to add this video will be SUPER handy if you crack a gear and have a donor tranny of ANY year (5mt that is). I will show how to swap out the gear sets. So all of you 02 WRX owners can possibly fix your trannies when you break them.

1st of course you need a donor tranny of course. I have purchased a few of them from salvage guys when the case is damaged.

As far as I can tell, all the 5mt gear sets can be swapped from case to case from 1990 to 2007, no crappola. But no guaranties either. But I have swapped quite a few gearsets from one year tranny to another.

There are two caveats though. 1st you will need the correct center diff if the gearset is newer, but you can use an older gearset in a new center diff. This is due to the way the 5th gear is setup.

The other is you need to use the correct pinion shaft. So you would not be able to just lift the gears out of a 4.11 and install them in a 3.9. You would need to swap the shaft. I cover this.
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Old 06-27-2008, 11:56 PM   #12
Mechie3
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I'd like one. Maybe get someone to even take screen shots and make it a printable writeup, like your engine teardown writeup (when are you going to do an engine build writeup?!!??)
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Old 06-28-2008, 03:34 AM   #13
ballitch
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Please dont forget the torque specs for the bolts you remove, it really helps to be able to search later on.......what am I talking about....this MIGHT get into the sticky section...




~Josh~
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Old 06-29-2008, 11:33 PM   #14
reddevil
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Default

Half done with the swap....

I have torque #'s to give out, but cannot stand 100% behind them, but I will use them. They come from a factory service manual, but they say the 10mm and 12 mm bolts, but we all know they are 12 and 14! ?
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Old 06-30-2008, 12:31 AM   #15
Tim Sanderson
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The manual is refering to the shank diameter not the head size.
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Old 06-30-2008, 07:09 AM   #16
fastwrx25
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love to see the video.

I'm sure you would be helping out lots of ppl down the line.

maybe I can then install a obx front lsd myself if I ever grow some balls
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Old 07-10-2008, 03:04 PM   #17
blacktalon606
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I want this vid as well!!! You never cease to amaze me man.
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Old 07-10-2008, 03:24 PM   #18
Back Road Runner
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I'm all for informational videos.
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Old 07-10-2008, 04:22 PM   #19
mister_skinny
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Default Front diff install

GIMMIE GIMMIE GIMMIE!!!
I need to swap out my STI Bell Housing, and this would help me out a lot!
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Old 11-14-2008, 07:46 PM   #20
unclemat
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So much for the video....
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