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Centre Diff Swap


Rosssub
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This is a merge of posts from my garage thread. Covering my BH5 GTB 5MT centre differential change to a Version 8 WRX centre diff:

http://www.clubsub.org.nz/forum/index.php?/topic/40292-rosssubs-gtb/&page=4

 

Started ripping the BH centre diff out this evening. After driving at 100kph for a while, then trying a tight turn it's locking up pretty bad. Car jerks forward violently as though all the CV's are stuffed. Also making it under steer easily at any speed when the centre diff's hot/binding.

 

Jacked up and GB oil drained:

BH5_B_Certre_Diff_Swap_01_006.jpg

 

Driveshaft out:

BH5_B_Certre_Diff_Swap_01_012.jpg

 

GB supported with a jack:

BH5_B_Certre_Diff_Swap_01_013.jpg

 

GB cross member removed

BH5_B_Certre_Diff_Swap_01_023.jpg

 

Here's the shifter linkages at the rear of the GB:

BH5_Centre_Diff_Replacement_02_001.jpg

 

Shifter linkage and stabiliser unbolted:

BH5_Centre_Diff_Replacement_02_004.jpg

 

Locking slide pins removed from shifter linkage knucle:

BH5_Centre_Diff_Replacement_02_008.jpg

 

After removing both locking pins (inner/outer) the shifter linkage knuckle will come off:

BH5_Centre_Diff_Replacement_02_011.jpg

 

Exhaust hanger bracket and transfer case rear cover unbolted:

BH5_Centre_Diff_Replacement_02_012.jpg

 

Rear cover (extension case) ready to come off:

BH5_Centre_Diff_Replacement_02_016.jpg

 

Using a flat head screwdriver and hammer to separate the transfer case/rear cover:

BH5_Centre_Diff_Replacement_02_017.jpg

 

Worked apart nice and evenly:

BH5_Centre_DIff_out_001.jpg

 

Centre diff and driven gear coming out:

BH5_Centre_DIff_out_003.jpg

 

Removed:

BH5_Centre_DIff_out_005.jpg

 

Driven gear shaft and centre diff slid out of rear cover:

BH5_Centre_DIff_out_006.jpg

 

Transfer drive gear removed from centre diff:

BH5_Centre_DIff_out_008.jpg

 

Gasket surfaces all cleaned up and ready for the replacement diff to arrive:

BH5_Centre_DIff_out_011.jpg

 

Here's the replacement centre diff, it's from a Version 8 WRX.

BH5B (TZ254) - Version 8 WRX (DA230)

BH5_B_Centre_Diff_Swap_04_001.jpg

 

BH5 - V7 WRX

BH5_B_Centre_Diff_Swap_04_002.jpg

 

New diff installed into rear casing then lubricated:

BH5_B_Centre_Diff_Swap_04_004.jpg

 

3-4mm bead of gasket silicone on the transfer case:

BH5_B_Centre_Diff_Swap_05_002.jpg

 

New center diff/rear casing installed and torqued to 40 Nm(29.7 ft-lb), then exhaust hanger bracket back on:

BH5_B_Centre_Diff_Swap_05_005.jpg

 

Shifter linkage knuckle and stay back on:

BH5_B_Centre_Diff_Swap_05_008.jpg

 

GB crossmember and driveshaft back in:

BH5_B_Centre_Diff_Swap_05_012.jpg

 

Just topping the oil up (3.5L), then it's time to set the new EBC up. :)

BH5_B_Centre_Diff_Swap_05_014.jpg

 

Here's a thread by Gazzy2000 covering swapping to an earlier phase 1 WRX/STI centre diff, centre casing and rear casing:

http://www.clubsub.org.nz/forum/index.php?/topic/14690-center-diff-gone-in-your-bh-heres-a-very-cheap-option/

 

Then DRFVDR's centre diff locking for RWD how to thread:

http://www.clubsub.org.nz/forum/index.php?/topic/20114-centre-diff-locking-for-rwd-how-to-by-uncle-darth/

 

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