[Es2] V8 torsen rear diff on coupe S2

Elijahallen92 at aol.com Elijahallen92 at aol.com
Mon Jun 20 20:14:22 EDT 2005

Ok guys, this seems like a very good upgrade for our cars, especially the  
ones making big power because of wheel spin coming out of corners. This was  
posted on the S2 forum and the directions look pretty straight forward. I would  
like to do this but don't have time and or the right equipment/knowledge to 
feel  comfortable doing it. Anyone out the want to whip up a batch of these? 
There  have been so many custom group buys lately I thought maybe someone would 
like to  do this one.

Here's a small how-to on swapping the open S2 diff for a V8 torsen  one.

I'll start this at the point where you have both diffs in front of  you on 
the bench.

- Drain all the oil from both diff's
- Remove both  the driveshaft flanges from both diff's
- Remove the casing-cover that sits  behind the driveshaft flange, on both 
diff's. That casing is bolted to the diff  housing itself with 9 bolts.
- Remove both diffs out of it's housing
-  Then remove the O-ring seal at the far end of the diff housing from both 
the V8  diff and S2 diff. 
The reason for that; is that one of the two driveshaft  flanges from the S2 
is different then from the V8. The V8 driveshaft flange has  a thicker diameter 
at the point where it seals with the O-ring. We need the V8  driveshaft 
flange eventually on the S2 diff housing.
These O-rings are metal,  and are pressed in the diff housing. They can be 
removed by driving them out  with a pendriver and a hamer from the inside out.
Ofcourse it will be better  to replace the V8 O-ring with a new O-ring. Just 
make sure its not damaged if  you use it or dried out.
- Press the V8 O-ring in the S2 diff housing. You  will notice that the 
inside diameter from the V8 O-ring is bigger then the S2  O-ring.

- Passing on to the diffs itself. 
- Remove the crown wheels  from both diff's (bolted with 10 bolts). And swap 
them around. So S2 crown wheel  onto the V8 Torsen Diff. Retighten the bolts 
at xx NM (will need to check what  NM's I tightened the bolts)
- Drop the V8 Torsen diff in its new S2  housing
- Make sure all bearings are clean. Apply some liquid gasket on the  surface 
where the casing-cover meets the diff casing. Then put the casing-cover  to 
close the diff again. 
- Retighten the 9 bolts
- Mount the V8  driveshaft flange on the side were you swapped the O-ring
And on the other  side IIRC the S2 driveshaft can be fitted.
- retighten the bolts from both  shaft flanges
- Check if there's any play on the diff bearings and that it  turns easily
- Fill the diff with some fresh oil. And check for leaks.
-  Get it back under the car asap!! And while you're at it, throw in a 
powerflex  diff rubber aswell.

Enjoy some sideways actions!!

I'm not  responsible if there's a failure because someone used this method to 
swap his  diff. If you do this swap, use your common sence and check every 
step for  yourself.

Cheers  guys!

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