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Old 07-29-2020, 09:04 PM   #1
catz4dave
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Default 04 6 Speed - 3.90 r160 Quaife rear diff problems

So against my better judgment I bought another STI bringing the total to 3.

It has an 04 3.90 6 speed swapped and originally was an 04 WRX, and the rear diff was swapped for a quaife Torsen type. Now onto the issues, it puts down 420whp w/ a 3076r.

For some reason the rear axles are not seating correctly, I pulled them both and could not find retaining clips in the rear diff. Car drives fine usually and can only feel axles flexing under heavy load. Any ideas where these clips could have gone ? I cleaned the stubs and the entrance to the rear diff on both sides well.

I also attempted to replace the cir clip, and the one I was given by Subaru was too large to fit flush in the space on the axle stub. Iím guessing the wrx axles were retained, but if that was the case then the c clips shouldíve been seated in the rear diff. Any ideas guys, Iím positive the clips were not in the diff, I have an upgraded Perrin diff cover, pulled that off and did not see anything. Axle stubs also had no scoring, essentially they will push in flush but not lock.

Other symptoms are loud noises from the rear only sometimes when backing up.
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Old 07-29-2020, 09:31 PM   #2
2slofouru
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Probably gave you the incorrect clips for the axles.

Oh crap, didn't consider the quaife internals. It's possible the R160 wrx axle clip locations are incorrect for the lsd. I didn't read it correctly and thought you had a R180 diff and inner cup swap at first. I'm still probably incorrect, but someone who's done that install a million times will see the thread if idiots like me bump it enough.

Last edited by 2slofouru; 07-29-2020 at 09:34 PM. Reason: Ooops!
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Old 07-29-2020, 09:36 PM   #3
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Originally Posted by 2slofouru View Post
Probably gave you the incorrect clips for the axles. Oh crap, didn't consider the quaife internals. It's possible the R160 wrx axle clip locations are incorrect for the lsd.


Thanks for reading and commenting; the part I tried was # 28333SA000. The car has driven fine for about 5k miles, the issue is new, I believe I might have mistaken the axle flexing for breaking traction before It got worse.
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Old 07-29-2020, 10:12 PM   #4
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Quote:
Originally Posted by catz4dave View Post
Thanks for reading and commenting; the part I tried was # 28333SA000. The car has driven fine for about 5k miles, the issue is new, I believe I might have mistaken the axle flexing for breaking traction before It got worse.
Is it possible the the front axle clips are a little larger and they gave you a front clip? When I search it comes up as a front axle clip.
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Old 07-30-2020, 01:32 AM   #5
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Is it possible the the front axle clips are a little larger and they gave you a front clip? When I search it comes up as a front axle clip.


Iím not sure; I pulled the rear axles the cheater way. Iíve looked around a ton and cannot find the correct c clip # apparently. From what I understand on the front axles the c clip stays on the axle stub, but on the rear axles it stays in the rear diff.
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Old 08-08-2020, 09:16 PM   #6
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805324010 did not work either; fit on the axle but wouldnít go into the rear diff.
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Old 08-08-2020, 09:25 PM   #7
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Being you have a different differential, the internal location of the clips may be different, and isn't lining up with the axle notches. I've read of some R160 diffs having rear axles with two different stub lengths. Do your axles have the same length and style stubs?

The clips in your Qauife diff may be too far in for your axle stubs to reach in and lock. You may need to swap different inner stubs/cups onto your axles. That or the clips have been removed from the diff. I've looked around but haven't found definitive information.




I'm surprised no gurus have chimed in...

Last edited by 2slofouru; 08-08-2020 at 09:34 PM.
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Old 08-08-2020, 09:56 PM   #8
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Same exact lengths
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Old 08-08-2020, 10:04 PM   #9
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So if the splines are engaging and they both slide in all the way, either the internal locking clips aren't there or they aren't matching the axle groove location. The groove in that axle is too shallow for a clip so yeah the diff has to have it.

Maybe you can try and use a long pick to locate the clip location inside the diff and measure and compare it to the distance on the axle.

Do both axles go in all the way? A damaged internal clip could also theoretically prevent the axle going in far enough to lock.
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Old 08-08-2020, 10:20 PM   #10
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Both axles seem to be able to slide in all the way. LR axle seats correctly. RR axle slides in all the way but will walk out of place, leak fluid, and is clearly not seated 100% after diving.
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Old 08-08-2020, 10:35 PM   #11
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Quote:
Originally Posted by catz4dave View Post
Both axles seem to be able to slide in all the way. LR axle seats correctly. RR axle slides in all the way but will walk out of place, leak fluid, and is clearly not seated 100% after diving.
I also read on another subie forum about a diff that has two clip locations on each side, to fit two different axle types. Can you see anything in either side of the diff that resembles a clip or slot for a clip?
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Old 08-08-2020, 10:38 PM   #12
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Default 04 6 Speed - 3.90 r160 Quaife rear diff problems

Hereís a pic of the diff. On the LR after the raised gears I believe I can feel the clip.



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Old 08-08-2020, 10:46 PM   #13
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Originally Posted by catz4dave View Post
Hereís a pic of the diff. On the LR after the raised gears I believe I can feel the clip.



I might not be much help but at least bumping this thread may catch the right person's attention.
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Old 08-08-2020, 10:54 PM   #14
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Originally Posted by 2slofouru View Post
I might not be much help but at least bumping this thread may catch the right person's attention.


Nah man I really appreciate your help! Thanks for the research you did, there does not seem to be a ton of info on this topic online.
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Old 08-17-2020, 11:08 PM   #15
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Any progress? I'm curious what's causing the issue.
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Old 08-18-2020, 09:49 AM   #16
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Quote:
Originally Posted by 2slofouru View Post
I also read on another subie forum about a diff that has two clip locations on each side, to fit two different axle types. Can you see anything in either side of the diff that resembles a clip or slot for a clip?
I sort of recall that was the case on some Quaife rear diffs. The clip (installed internally the diff) has to be moved into the other machined slot. The the axle slot would then mate to the clip and stay seated.
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Old 08-28-2020, 09:00 PM   #17
catz4dave
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Still no progression this on my end, going to drop the diff when I have a chance
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Old 01-13-2021, 10:25 PM   #18
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So I am happy to say I can come back to this thread with good news. After quite a bit of time searching I figured out what I can say is the definitive answer for getting axles to lock in on the quaife.

First and foremost the rear hubs are different on both sides.

On the RR (pass) side there is two channels as can be seen in the picture I posted above. For my 04 WRX that has open diff axles I had to use Circlip. #805324010 aka (24x2.3) and seat it in that second channel looking at the hub or the first channel on the diff side. The first groove is for cars with VSLD axles.

On the LR (driver) side there is two groves really close to each-other, it looks like there is only one possible configuration with this side. I do not have a circlip. in my diff or on my axle re: LR side, and it was not leaking like the RR side was. I am currently searching for the correct Circlip. Part # is for the clip that sits on the LR open diff rear axle. If anyone has this please post it. I have tried the above referenced part number and Circlip. Part #28333SA000 which I believe is from a front axle however it is the right gauge but slightly too large.

The strangest part about this is that the clips that were originally seated seem to have vanished completely, like I mean, there is no metal shavings or clips anywhere in the diff. And the car drove fine for some-time before this ever became an issue.
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