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Thread: Serendipity's comprehensive AE86 Rear End swap.

  1. #1
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    Serendipity's comprehensive AE86 Rear End swap.

    While in the midst of searching for parts necessary for my 5 speed swap http://www.dorikaze.net/showthread.p...wap&highlight= my Dad and I found a late model (Kouki) GTS rear end. It was missing the Lines and Fittings, and was pretty rusty, but we decided to grab it.


    PROJECT LENGTH JAN 2011-PRESENT


    For helping me find parts, and for consultation, thanks be to:

    Warren
    Pitobread
    Brian
    JayWhit
    DugWillis
    DiscoQuinn
    VISean

    And thanks again to my Dad for his supervision and contribution to the project.


    Services and Parts Rendered

    EP Importers - TRD and OEM Toyota Parts
    Bullfrog Transmission - Dismantling and Inspection of Differential
    Clark's Machine Shop - Removal of Axels, and Machine Work
    Key 2 Machine Shop - Machine Work
    Weir Performance - Ring & Pinion, Differential Bearing Kit, Wheel Bearing Kit, Overbearing Kit (usually sold by mothers), Solid Pinion Spacer
    Island Powdercoating - Do you have to ask?
    Driver's Edge, Vancouver BC - Brake Rotors and Pads
    Last edited by Serendipity; 06-08-2013 at 07:29 PM.

  2. #2
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    PARTS LISZT AND PICTURES:


    DIFFERENTIAL
    Axel Housing, OEM used
    Differential Carrier Housing, OEM Used
    AE86 Zenki Axels (X2), OEM Used
    AE86 Zenki TRD 2 Way LSD,
    Previously installed but never used
    Redline 75W90 Synthetic Gear Oil
    4.778 Ring & Pinion, Weir Performance
    Bearing Adjust Lock,
    -Single Type 41310 22011
    -Double Type 4137 22011
    Diff Housing Bolts, short (X9) 90116-08418
    Diff Housing Bolts, long (X1) 90116-08419
    Diff Housing Lock Washers, (X10) 94512-00800
    Diff Housing Nuts (X10) 90170-58204
    Differential Vent Plug
    Magnetic Drain Plug (X2) 90341-18057
    Crush Washer (X2) 12157-10110
    Panhard to Housing Bushings (X2) 90385-20001
    Panhard to Housing Washers (X2) 90201-12036
    Panhard to Housing Nut 94184-61200

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    DIFFERENTIAL REBUILD KIT, Weir Performance
    Inner Race Bearing, Koyo
    Outer Race Bearing, Koyo
    Outer Pinion Bearing, Koyo
    Inner Pinion Bearing, Koyo
    Pinion Seal
    Solid Pinion Spacer & Shims
    Pinion Nut & Washers

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    AXELS
    Wheel Studs (X8) I forget the Part number???
    Bearing Kit, Wier Performance
    -Rear Wheel Bearings (X2), Koyo
    -Axel Retainer (X2) Koyo
    -Axel Seals (X2) OEM Toyota
    -Hub Retainer (X2) OEM Toyota

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    BRAKES ET AL
    Pilenga OEM Rear Discs, new
    Porterfield R4S Rear Pads, new
    AE86 GTS Backing Plates, used
    Backing Plate Bolts (X8) 42184-22011
    Backing Plate Nuts (X8) 94181-11000
    Hub Bolts (X8) 90942-02047
    E Brake Cable RH 46420-2300
    E Brake Cable LH 46430-2200
    E Brake to Body Brackets (X2) 90461-12121
    Retaining Pin (X2) 46458-50010
    Retaining Clip (X2) 96991-10080
    Cotter Pins (X2) 90240-08040
    U-Clips (X3) 96991- 10080
    ??? 91611-B0616 Can't remember what this is
    ??? 96991-10080 Can't remember what this is
    Line Union 90413-10098
    Brake Line Hangers (X4) 96221-30705
    Brake Line RH (Hard) 47324-12150
    Brake Line LH (Hard) 47325-12150
    Brake Line Hanger Bolts (X4) 91611-60612
    Brake Hose (X2) 96940-32555

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    4 LINK FASTENERS
    4 Link Bolts (X2) 90101-12044
    4 Link Washers (X2) 90201-12010
    4 Link Nut (X2) 90179-12025
    Last edited by Serendipity; 05-31-2013 at 09:16 AM.

  3. #3
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    TEARDOWN

    I brought the Rear End Assembly to Bullfrog Transmission, the shop that did a wonderful job of rebuilding my T50. Unfortunately, the bearings were seized, and so they recommended that we take it to Thompson's Machine Shop and have them handle the disassembly. Seized bearings are not uncommon for a factory Rear End that hasn't had it's axels removed.

    Using their Hydraulic Puller and some heat, the Machine Shop was able to remove the Axels, and subsequently the Third Member. The Axles were in straight and in good shape. I also had them check the trueness of the bores. Why?

    I read the information on Wier Performance's website, and called Spence to corroborate what I had read. He has seen many Toyota 6.7" Rear Ends, and found that they occasionally have flaws in the trueness of the bores. The machine shop proved that the bores were true.

    The next step was to Have Bullfrog Transmission tear down and inspect the Third Member. As it turns out, the Differential was in good condition. The Ring & Pinion was also in good shape. However, both went to new homes as I wanted an LSD and a taller Final Gear.

    The last bit of Machine work was done by Rod at Key 2 Auto. In days of Yore, that was the machine shop which Metro Toyota dealt with. Rod also did an excellent job with my cylinder head rebuild, and restoring my 4AC flywheel. I had him check the threads and repair a few that needed some TLC.

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    Last edited by Serendipity; 06-08-2013 at 07:34 PM.

  4. #4
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    RESTORATION


    PREPARING THE DIFFERENTIAL HOUSINGS FOR RESTORATION

    As the saying goes, "In Toyota we Rust." Considering that there were bearing surfaces I did not wish to alter or damage by media blasting, I had Victoria Plating treat the parts in a "Pickling Tank"; a tank with a solution corrosive enough to remove the oxides, but not the metal.

    Since I would not be finishing the restoration right away I also had them Silver-Cadmium Plate the parts to prevent the from oxidizing. Doing so also coated the inside of the bearing surfaces, reservoir area, and threads, etc. "Thank you Captain Obvious" you say. Restoration is also about prevention.


    AFTER PLATING

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    AFTER POWDER COATING

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    Last edited by Serendipity; 05-27-2013 at 08:11 PM.

  5. #5
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    Serendipity's comprehensive AE86 Rear End swap.

    ASSEMBLY

    The differential was assembled at Bullfrog Transmission. The Brakes and lines were installed at "Business Casual". Warren & Pitobread are my Wingmen.
    Last edited by Serendipity; 06-08-2013 at 07:36 PM.

  6. #6
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    "SHOULD I PAINT THE DIFFERENTIAL OR POWDER COAT IT?"

    Thinking ahead, I considered how I would clean up the Differential Housing & Carrier, and whether I would Powder Coat or Paint it. I consulted Spence Wier. His advice was that Powder Coating would be best if the Rear End was going into a Show Car, but that it was best to Paint the Rear End of a Performance Car.

    I personally disagree. I think that a Drift Car's Differential would be best Powdercoated to protect it from all the debris it's subject to, and that a Show Car would be better to paint, as you could easily repair it, and add a nice clear coat. I do however, understand what Spence means. In the hands of an inexperienced Powder-Coater you could be playing craps with your Diff Housing.

    He went on to say that during the process of Powder Coating, the item to be coated is placed in an industrial oven to off-gas. If the company sets this temperature too high, the heat may relax the welds in the fabricated part of the housing, resulting in a warping.

    In his experience, some Differential Housings had returned from the Powder Coating shop just fine, and some needed to be straitened; it really depends on how hot the off-gas temperature is.

    I called both local Powder Coating businesses in Victoria to find out what they set their off gas temperatures to.

    Victoria Powdercoat: 400-425F for 30-60 minutes.
    Island Powdercoating: 400F for 5-10 minutes.


    A second choice is to paint the Differential Housings with a single stage Urethane based paint (Gloss Black) from Rondex. My favorite restoration shop Coachwerks uses this on their Powertrain restorations, Gas Tanks, and anything else going underneath the chassis. They used it to paint my gas tank.


    Conclusion:

    I had Island Powdercoating finish off my Diff Housing Parts. It looks great, and is an industrial strength coating. I could smack it with a hammer if I wanted to.
    Last edited by Serendipity; 06-08-2013 at 07:40 PM.

  7. #7
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    Serendipity's comprehensive AE86 Rear End swap.

    Comic Relief provided by Last Latvian
    Last edited by Serendipity; 06-08-2013 at 04:35 PM.

  8. #8
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    Quote Originally Posted by Serendipity View Post
    Additional topics to be discussed:

    COATING THE INSIDE OF THE DIFFERENTIAL HOUSING
    why? It cost money, it could cause issues if the paint didn't hold and got in your diff/oil. As you mentioned powder coating is for show cars, are you going to be pulling your diff at events so people can see your internally coated diff housing? This idea just seems to comprehensive for me


    Quote Originally Posted by woodenturn View Post
    DK should ban such nonsense. 2 cents~ sr86 www.dorikaze.net/showthread.php?32933-Elizabeth

  9. #9
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    Quote Originally Posted by LastLatvian View Post
    why? It cost money, it could cause issues if the paint didn't hold and got in your diff/oil. As you mentioned powder coating is for show cars, are you going to be pulling your diff at events so people can see your internally coated diff housing? This idea just seems to comprehensive for me
    Aha! I haven't yet done anything to the inside, Sir. I only brought up this topic Because Coachwerks has the inside of their Differentials coated, and I'm curious.

    As far as I know, when the Diff operates, it creates a mist that coats the inside, nest-ce pas? BTW, where did you find that photo of me? Haha.

  10. #10
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    Quote Originally Posted by Serendipity View Post
    Aha! I haven't yet done anything to the inside, Sir. I only brought up this topic Because Coachwerks has the inside of their Differentials coated, and I'm curious.

    As far as I know, when the Diff operates, it creates a mist that coats the inside, nest-ce pas? BTW, where did you find that photo of me? Haha.
    Odd, curiosity killed the cat and coachwerks sounds like a place rich people go to spend money on cars they don't know how to work on, nest-ce pas? Misted diffs sound to mysterious for me but now that I think back I always have had issues with 80-90w redline oil getting in my eyes when I crack the seal, just mystifying. I've heard the trick is to get a left handed wrench from Coachwerks to adjust the flux core capacitor on your differential housing so its not a rain forest in there. Then you can do the kessel run in under 4 parsecs! Sometimes oil if overheated lgets frothy like a coffee thats about it, paint won't make a difference, a cooler would. I found the photo in my personal collection... slurp.

    Last edited by LastLatvian; 03-04-2013 at 11:00 PM.

    Quote Originally Posted by woodenturn View Post
    DK should ban such nonsense. 2 cents~ sr86 www.dorikaze.net/showthread.php?32933-Elizabeth

  11. #11
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    that's garbage, the fastest ship out there could only manage the kessel run in 12 parsecs

  12. #12
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    Fun facts:

    This is dope
    BCWORKS

  13. #13
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    Pictures Updated.

  14. #14
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    It's looking pretty sweet!

    Click image for larger version. 

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  15. #15
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    Nice work Adrian!

  16. #16
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    Backtrack to February. The LSD that arrived was a Zenki. I had to decide what to do. Sell it, and buy a Kouki (which would definitely not be new) or sell my axels and buy a Zenki pair. I did the latter.

    Robert at EP Importers was more than helpful in finding me a pair of Zenki axels with good bearings, although they will be replaced with the new bearings and retainers I got from Weir.

    Fast forward to today: my Zenki axels have arrived in Vancouver; I expect to see them next week. Once I get them plated and painted this project will be ready to install.

    Countdown 3 weeks.
    Last edited by Serendipity; 05-02-2013 at 11:42 PM.

  17. #17
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    Does that mean miata itbs are also landed?

    Sent from my GT-I9100M using Tapatalk 2
    1987 Corolla GTS Hatch | 1985 Corolla GTS Coupe | 1987 Corolla GTS Coupe | 1992 Tercel CE | 1992 Paseo | 2003 Corolla CE | 1974 Corolla 4 Door | 1978 Corolla Coupe | 1979 Corolla Hatch SR5 | <3||||||1990 Miata |||||| <3
    I like Toyota's wanna fight about it?

  18. #18
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    Quote Originally Posted by pitobread View Post
    Does that mean miata itbs are also landed?

    Sent from my GT-I9100M using Tapatalk 2
    Unfortunately, those are arriving in the next shipment.

  19. #19
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    Well fudge. how am I going to unleash my inner ricer now?

    Sent from my GT-I9100M using Tapatalk 2
    1987 Corolla GTS Hatch | 1985 Corolla GTS Coupe | 1987 Corolla GTS Coupe | 1992 Tercel CE | 1992 Paseo | 2003 Corolla CE | 1974 Corolla 4 Door | 1978 Corolla Coupe | 1979 Corolla Hatch SR5 | <3||||||1990 Miata |||||| <3
    I like Toyota's wanna fight about it?

  20. #20
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    This looks too expensive for my cheapo blood. Didn't realize you would still be able to buy rear hardlines. Probably still a lot cheaper to make them.
    1JZ 1984 Celica GTS
    1UZ 1981 Corolla sedan
    ? 1972 Celica race car

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