TC3 Diff Re-build

[Cam]

I have a second hand TC3 and I am planning to re-build the diffs. It is the first time I have had anything to do with diffs.

Does anyone have any advice or experience that would help me rebuild the diffs with the minimum of hassle ?

Is anyone aware of any webguides/websites for diff building ?

Cheers

Cam ::)

[burgie]

right then, stripping diffs and rebuilding them is not hassle, it's maintenance. If you take your time and pay attention to what you are doing then it will be problem free.

when you strip a diff unit down, only do one at a time, just so you don't get confused, and you can easily tell if you have any parts left over, and I recommend that you do this on a tray or similar, so the little diff balls don't hide in the carpet.

strip the diff unit down and leave it all to soak in white spirits or other de-greasing agent, for a couple of hours, and ensure that everything is thoroughly clean, and free from grit etc. when you are ready to put everything back together. Use a soft cloth to dry everything.

use the correct grease (white grease) on the diff balls, and the correct grease (black) on the thrust bearings. This is important.

then re-build the diff following the instructions to the letter, and as long as you have used the grease in the right places, and used enough of it, but not so much as it seeps out everywhere, then once re-built you will have a nice smooth diff unit.

It may be worthwhile to buy new carbide diff balls if you are going to strip the unit down, as they are only cheap and it will ensure that the diff is built with a full set of ROUND diff balls, as it is possible to put flat spots on the diff balls.

This is how I rebuild the diffs:- I put grease on the diff plates (the silver things with a flat spot on the internal diameter) and then in the holes of the diff wheel BEFORE I put the diff balls in it. I then put the diff wheel on the partially assembled short out drive, and then put the balls into the holes.

the last thing I build is the screw that bolts the output shafts together, and keeps the thrust races in place. Take care to ensure that the little thrust balls are evenly spaced before putting them into the outdrive.

I tend to put the outdrive onto the bolt rather than put the bolt into the outdrive. this ensures the thrust balls don't fall off.

This method has so far only ever resulted in nice smooth diffs, that don't grind and don't slip.

you don't need web guides or websites devoted to car maintenance. you have (should have) the instruction book. This is the best source of information, and you would do well to read it!

[nicholas mitchell]

phew, i think chris has got it spot on there.
8)

[Cam]

Chris,

Thanks for the advice. I am getting a dif rebuld kit from associated (AS3926) so I expect that it will contain everything necessary to do the job, including the appropriate grease.

You mentioned possibly changing the diff balls, does anyone know if they come with the kit or need to be purchased separately ?

Cheers

Cam ::)

[burgie]

Cam, the diff balls come with the rebuild kit i think, but they are NOT the tungsten carbide chappies that i mentioned i dont think.

sorry to be vague, but i bought me carbide balls seperately, and don't use the rebuild kits!

[Cam]

Cheers, I'll post once I have finished hopefully to say it all went well

Cam ;D ;D

[webba]

Only the thrust balls come with the diff rebuild kit. At least, they did with the one i had.

[Cam]

Did the diffs last night. I now have a smooth action as opposed to a gritty/slipping action I had previously. I assume that they should now perform a lot better.

I have one more question. The manual advises to drive for a pack then re adjust tension. Can this be done by simply adjusting the bolt holding the thrust bearings in place without diassembling the diff case again ?

Cheers

Cam

[Southwell]

Yes just put a allen key in one side and hold the other wheel and turn. It can be done by just removing the turnbuckle.
When you first turn on the car hold one front and one rear wheel and put the motor to turn fairly slowly for 30 seconds this helps with the bedding in process