Serendipity's comprehensive AE86 Rear End swap.

[Serendipity]

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

[Serendipity]

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





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




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




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



4 LINK FASTENERS
4 Link Bolts (X2) 90101-12044
4 Link Washers (X2) 90201-12010
4 Link Nut (X2) 90179-12025

[Serendipity]

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.

[Serendipity]

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




AFTER POWDER COATING

[Serendipity]

ASSEMBLY

The differential was assembled at Bullfrog Transmission. The Brakes and lines were installed at "Business Casual". Warren & Pitobread are my Wingmen.

[Serendipity]

"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.

[Serendipity]

Comic Relief provided by Last Latvian

[LastLatvian]

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

[Serendipity]

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.

[LastLatvian]

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.

[Duy-]

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

[Warren]

Fun facts:

This is dope

[Serendipity]

Pictures Updated.

[Serendipity]

It's looking pretty sweet!

[matt t]

Nice work Adrian!

[Serendipity]

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.

[pitobread]

Does that mean miata itbs are also landed?

Sent from my GT-I9100M using Tapatalk 2

[Serendipity]

Does that mean miata itbs are also landed?

Sent from my GT-I9100M using Tapatalk 2

Unfortunately, those are arriving in the next shipment.

[pitobread]

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

Sent from my GT-I9100M using Tapatalk 2

[clay72]

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.