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Old 04-23-2007, 11:08 AM   #1
spit_heron
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Default Center Diff Failure and Replacement

edit: im gonna try to resize pics

Car: 2002 Wrx 120k miles, about 60k at stage 2.

Symptoms: Very loud rotational grinding noise coming from under seat during accel and decel

Suspected the center diff due to oil coming out of shift linkage area and extension case.



Drained the trans oil and it looked contaminated with a shiny liquid.

Take the extension case off the trans and find this:







So it looks like the seal? on the diff blew and chunked itself in the extension case, which in turn mangled and chipped a few teeth on both the drive and driven gears. It looks like I need a new diff, new drive gear and new driven gear at minimum.

A few questions before I start ordering parts. Referencing this:


I cant find washer number 2. Did it explode or am I missing something? Same for washer number 1, should I be able to see this washer with what I have apart?
The bearings on the driven gear look fine, but I think I will just order new ones to be safe. I guess these need to be pressed on, can any place with a press can do this, or is this something I should leave to a dealer.

Finally, let me say that the failure is my fault and was avoidable. I had a slow leak in my front driver side tire that I let go too long and drove a fairly long distance with too great a tire pressure difference from front to rear.
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Last edited by spit_heron; 04-23-2007 at 11:25 AM.
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Old 04-23-2007, 07:32 PM   #2
St.race
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If it's your first time do not do it yourself. Washers have a different thickness and you will only know which one you need during reassembly. And any place with a press can do the job right if they know what they are doing.
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Old 04-23-2007, 07:43 PM   #3
spit_heron
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well, it looks somewhat straight forward per the FSM.

If someone knew the thickness of the ST guage it would help.

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Old 04-23-2007, 10:43 PM   #4
REDI-wgn
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ANy shop with a press, provided they have all size adapters, should be able to do it.
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Old 04-23-2007, 11:50 PM   #5
WRXINTX
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Quote:
Originally Posted by spit_heron View Post
well, it looks somewhat straight forward per the FSM.

If someone knew the thickness of the ST guage it would help.



I tried to find that out for over a month with my subaru dealership....

I think we should call Andrewtech/Gearboxtech.com and buy the tool from them or ask them what the thickness is....
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Old 04-23-2007, 11:52 PM   #6
WRXINTX
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Quote:
Originally Posted by spit_heron View Post
edit: im gonna try to resize pics

Car: 2002 Wrx 120k miles, about 60k at stage 2.

Symptoms: Very loud rotational grinding noise coming from under seat during accel and decel

Suspected the center diff due to oil coming out of shift linkage area and extension case.



Drained the trans oil and it looked contaminated with a shiny liquid.

Take the extension case off the trans and find this:







So it looks like the seal? on the diff blew and chunked itself in the extension case, which in turn mangled and chipped a few teeth on both the drive and driven gears. It looks like I need a new diff, new drive gear and new driven gear at minimum.

A few questions before I start ordering parts. Referencing this:


I cant find washer number 2. Did it explode or am I missing something? Same for washer number 1, should I be able to see this washer with what I have apart?
The bearings on the driven gear look fine, but I think I will just order new ones to be safe. I guess these need to be pressed on, can any place with a press can do this, or is this something I should leave to a dealer.

Finally, let me say that the failure is my fault and was avoidable. I had a slow leak in my front driver side tire that I let go too long and drove a fairly long distance with too great a tire pressure difference from front to rear.


I have a perfect set of 1.1 :1 transfer gears with good bearings still on them if you are interested in buying these used.....

I think new, everything was about $290 for bearings and all....

I would happily take $200 shipped and save you the hassle of having bearings pressed on and off.....


Let me know

RYNO
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Old 04-23-2007, 11:57 PM   #7
WRXINTX
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Btw, the cases are what are slightly different usually..... the actual gearsets are spot on perfect every time.....

so, if you have your washer/s and they are in good shape, you can stack and gauge them with the new gears in and make sure it is all good to go....


Also, did you find a good used center differential???

I have two units myself that I am looking to sell....

I was keeping them as spares....

I am asking $250 for the center differentials in good shape....

RYNO
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Old 04-24-2007, 12:01 AM   #8
WRXINTX
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I have broken three sets of stock output shafts..... and one center diff....

I had broken a set of output shafts and didn't realize it until I started getting the clunk clunk clunk.... thud!!!! tick tick tick... from the center diff....

The rear ouput shaft had broken clean in two pieces going into the driveshaft and was no longer pulling the rear wheels, thus causing the center diff to try and transfer all torque to the front wheels only....


My car makes about 600whp, so I have broke some parts to be sure....

Now, I have a set of experimental PPG unbreakable output shaft gears in and gonna hit them with all I got....


The set of gears you will get are in good shape and have never been raced on, so you will have no worries of breakage...

these shafts are so brittle, they just snap when they break....

"POP" and that's all she wrote...
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Old 04-24-2007, 11:21 AM   #9
spit_heron
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wrxintx, thank you for your help. I may take you up on your offer.

Can someone confirm if these two parts came of the center diff itself?

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Old 05-08-2007, 09:26 PM   #10
Raiden
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Did you remove the center diff section without removing the trans? If so how hard is this to do? I am having this very same problem and was told by the dealer that I need my carrier bearings replaced. If I can remove the center section myself and take it to them that would save me about $500 dollars in labor for the dealer to remove the trans.
Thanks in advance
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Old 05-09-2007, 12:48 PM   #11
Tim Sanderson
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Quote:
Originally Posted by spit_heron View Post
wrxintx, thank you for your help. I may take you up on your offer.

Can someone confirm if these two parts came of the center diff itself?

Yes sir. Those two pieces were both part of the same piece. Originally it was a 3 layer snap ring type thing that holds the diff's end cap on.
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Old 05-09-2007, 04:34 PM   #12
spit_heron
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Quote:
Originally Posted by Raiden View Post
Did you remove the center diff section without removing the trans? If so how hard is this to do? I am having this very same problem and was told by the dealer that I need my carrier bearings replaced. If I can remove the center section myself and take it to them that would save me about $500 dollars in labor for the dealer to remove the trans.
Thanks in advance
yeah, it was fairly straight forward. I followed this:
http://www.scoobymods.com/forums/showthread.php?t=6049

Except instead of removing the transfer case like he needed to do, you only need to remove the extension case to access the center diff.
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Old 05-20-2007, 11:46 PM   #13
Raiden
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Awesome
Thanks for the link.
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Old 05-21-2007, 01:57 PM   #14
340Duster
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the washers are different thicknesses to setup the bearing preload on the tapered roller bearings of the transfercase. I'm working on the exact same thing right now putting mine back together with a new diff and new bearings. And as a slight thread jack, WRXINTX, how much are the PPG transfer gearsets? I snapped the rear output shaft clean in half an inch above the drive shaft splines and am just putting in a stock set that has been cryoed.
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Old 07-13-2008, 02:45 AM   #15
richard donovan
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Quote:
Originally Posted by spit_heron View Post
well, it looks somewhat straight forward per the FSM.

If someone knew the thickness of the ST guage it would help.

it doesn't matter what the thickness is of the standard , the only thin that matters in the difference between he standard and the measurement you take with the depth mic. so if its 1 inch and you measure 1.005 that means the shim has a .005 gap (or 1.005-1.000 = .005 thousandths of an inch) so no need to find out the thickness of the ST gauge, its not relevant
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Old 07-13-2008, 02:57 AM   #16
hybrid gti 2
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I have wondered about this. I guess I don't need one yet.
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Old 07-13-2008, 03:12 AM   #17
powertothewrx
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Thats whats left of the locking ring on the back of the center diff.
I no longer had one but many more smaller pieces.
It doesnt like to much torque aplied and thats what fails most of the time.
Some guys weld the back together to prevent that.
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Old 11-30-2008, 06:04 PM   #18
andrewt461
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can't seem to break the seal on the extension myself.
Any hints here?

where is a good point to try and pry this thing off?
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Old 11-30-2008, 07:31 PM   #19
Tim Sanderson
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Quote:
Originally Posted by andrewt461 View Post
can't seem to break the seal on the extension myself.
Any hints here?

where is a good point to try and pry this thing off?
There are two alignment dowels. Tap them down and then you can jar the piece loose with a dead blow hammer.
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Old 12-01-2008, 12:15 AM   #20
andrewt461
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was doing that - didn't work for me too well...

ended up able to pry it off after much effort

thanks tho!
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Old 09-30-2011, 01:14 PM   #21
shamrock 05
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OK, for the plate that unbolts from the trans to pull the center diff out, how its covered in oil......thats transmission fluid correct? And couldnt you have just kept an eye on the trans fluid level then this may not have been so bad? Meaning it would have just been a center diff replacement rather than all those other parts?

Cause I am having the same prob, I got under the car the other day to look at the shifter bushings and noticed the oil residue on that plate and I checked the trans fluid and it was still covering the "F".

Ideas/opinions....and right now I dont have $1000 for parts and labor to fix the center diff, but it will be done within the next few weeks/month.
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