[Es2] Re: V8 torsen rear diff on coupe S2

Mark Wetzel mark.wetzel at verizon.net
Tue Jun 21 22:34:43 EDT 2005

I was thinking the same thing. Checking the shims and run-out would seem a necessity.

>From: Bernie Benz <b.benz at charter.net>
>Date: Tue Jun 21 17:05:07 CDT 2005
>To: es2 at audifans.com
>Subject: [Es2] Re: V8 torsen rear diff on coupe S2

>I'm a Digest lurker on this es2 list, but can't lurk without comment about
>your subject "how to" swap instructions.  Are you not mixing parts from two
>different shim matched assemblies without mention of the absolute necessity
>for reshimming?  Check the final drive assembly procedures in any Bentley!
>This is no simple task, and absolutely essential to the successful overhaul
>of any Hypoid final drive.
>> Message: 1
>> Date: Mon, 20 Jun 2005 20:14:16 EDT
>> From: Elijahallen92 at aol.com
>> Subject: [Es2] V8 torsen rear diff on coupe S2
>> To: es2 at audifans.com, billzcat1 at hotmail.com,
>> contact at euro-audi-parts.com
>> Message-ID: <a0.2acde754.2fe8b5d8 at aol.com>
>> Content-Type: text/plain; charset="US-ASCII"
>> 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.
>> Elijah
>> 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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