Differentials

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Differentials

Postby UptownSport » Fri Dec 17, 2010 5:49 pm

Transmission, per se, is an excellent piece. Differential is a different story.
The pin will gall in the gears, spin, shear the retainer pin and come out the case, causing catastrophic transaxle failure.
(THINK this was Doug's)
Image

You have several choices here:

1. Install differential saver tabs 5134957AA:
Concept is to let the pin 'full-float', like a wrist pin in a bushed connecting rod.
NOTE: Don't install the little retainer pin. It won't allow the pin to full float. You cannot install the retainer pin
with a the new Mopar differential pin, there's no hole. (see below)
We usually stock tabs ($3-4 ea), and new pins (~$16).
Image
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2. Install and OBX/Quaiffe. Both of these are suited for road racing. Our OBX is simply amazing!
Example, take a right hand turn, give it gas. Instead of the inner (Right)(unloaded) tire spinning, the driver's tire gets
power and the car takes off!! You'd better be holding onto that steering wheel!

OBX fix See Below.

3. Phantom Grip/S-Spring: Meh. HUGE amount of torque for little friction on little gears.
Something similar: viewtopic.php?f=5&t=687
Guys grind the side gears for more 'swept' friction surface, removing the little 'bump'.

S-spring: viewtopic.php?f=20&t=325

4. Spool/Weld the gears. Good for drag, i guess. Tires'll bind like a MoFo if you turn!
Image
Dunno what happens if you break an axle, get a close-up look at the wall?


Tull Bearing in north stocks the differential bearings if it needs them, search for real Timkens online.
5134957AA
4659142ab

Re-installing the bellhousing:
I suggest using a standard 1/2" socket on the four metric ring gear bolts, 60ftlbs, use RED loctite.
Sealing Case: Loctite #518 Gasket Eliminator
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Pack the race in grease, bearing won't fall out when you re-install, ensure the bearing is installed correctly, it's NOT symmetrical:
Image
wiggle the bellhousing and shift shafts, it'll fall on sooner or later.
bust0023 wrote:My car's got some rust on the doors too. Fortunately for me, I don't give a shit.
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UptownSport
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OBX LSD Repair UpDated 5/2012

Postby UptownSport » Fri Dec 17, 2010 5:50 pm

OBX Repair. Mines in and works- Radically different feel when both tires actually grab in a corner!!!
Wicked differential IF there's no huge flaws.
(Some updates on 5/2012 after installing a 2d OBX on our other Neon)

#1 REMOVE CLIPS FROM THE AXLES!!!!:
No way an axles coming out if it had a clip (backside of side gear)
Image
Steve wrote:I'm just fortunate it was the passenger side axle that stuck. At least I could get to it. If it had been the drivers side...
It's an M8x1.25x45mm
It's a 12.9 bolt which would put it at 27ft/lbs according to the FSM.
Thanks :)
Steve

OE side gear bevel:
Image

Tapered bolt recesses (One bolt was loose, others varied):
Image

Nothing wrong here:
Image
5/2012 Bellvilles were installed incorrectly out of box. At least one had no 'bell' to it!
If anyone needs bellevilles, I got PN 28-12.2-1.2 from key bellevilles inc.
5/2012 Used McMaster-Car PN 96445 K278 28x14.2x1.5
Steve wrote:Could the center assembly be in backwards? The gears and spring washers (btw, one of mine looked exactly like the picture you posted. The rest where fine). If I'm remembering correctly turning it around might give more room for the axle to seat. Of course I was paying more attention to getting it back together correctly than if it was correct to begin with.
Steve

The center assembly floats, appears the same on both sides.
It presses against the side gears.
Dunno if it just keeps the play out of them or somehow un/loads one side. (It seems it's a built in 'Phantom-Grip" for light
loads)

Another couple of those bellvilles are broken.
Old Washers:
Image

New washers:
Image

Side by Side:
Image

The axle didn't quite fully go in one side even before the bearing.
I don't know if it needs to go in that far; ~ 3/16"

One of the differential bearings went on so tight it actually constricted the bore, making the axle extremely tight; brake honed.
(5/2012 Same thing)
My Brother took his expenso-Starrett calipers and said the OBX
bearing surfaces are oversize vs. OE- Hence the constriction. :roll:
(5/2012 Journals were exactly to OE spec)
Hope the bearing doesn't break. (5/2012 Hasn't broken yet!)

5/2012 Our latest had some porosity:
Image

The axle didn't quite fully go in one side even before the bearing.
I don't know if it needs to go in that far; ~ 3/16"
Honed one end of axle bore a bit, fine now. Wonder if some people have twists from running slicks.

The side gears inside differential are designed to float, tap w/ a dead blow
hammer on the housing made axles fall right in.
bust0023 wrote:My car's got some rust on the doors too. Fortunately for me, I don't give a shit.
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UptownSport
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Location: Uptown

Re: Differentials

Postby UptownSport » Fri Dec 17, 2010 8:03 pm

Tull Bearing
2530 2d St. N Mpls
(612) 588-1185
Stocks Differential Side Brgs: Set Number: BCA A18

Timken JL69349
Width: 17.00mm = 0.6693 inch
Inside Diameter: 38.00mm = 1.4961 inch
Cone length: 13.5001mm = 0.5315
Mopar Bearing Number:
4567025AB $16.60
Front suspension - Suspension components - Wheel bearings
Wheel bearings, inner bearing, full size vans, w/o b350 van 1984 - 1991
WHEEL BEARINGS, Inner - 2WD, 1992-96 1992 - 1996
WHEEL BEARINGS, All Models, Inner, 5 Stud Rotor - 2WD 1984 - 1993
WHEEL BEARINGS, INNER, Full Size Vans, w/o 4000lb Axle 1992 - 1996
Part number 4567025 was superseded by part number 4567025AB.


Race ('cone') JL69310 Outside Diameter: 63.00mm = 2.4803 inch
Mopar Cone:
4567022 $10.10
BRG PKG DIFFERENTIAL


Ring Gear teeth count 106

Differential brg shims (62mm):
Stk PartNumb mm inches Price
O 4883546AA 0.42 0.0165 $3.60
O 4883545AA 0.46 0.018 $3.60
x 5222345 0.5 0.0197 $16.95
- 5222346 0.54 0.0212 $30.60
- 5222347 0.58 0.0228 $16.95
- 5222348 0.62 0.0244 $16.95
- 5222349 0.66 0.026 $16.95
- 5222350 0.7 0.0276 $16.95
- 5222352 0.78 0.0307 $16.95
- 5222353 0.82 0.0323 $16.95
x 5222355 0.9 0.0354 $16.95
x 5222356 0.94 0.033 $16.95
- 5222358 1.02 0.0401 $16.95
- 5222359 1.06 0.0417 $12.95
- 5222362 1.18 0.0465 $16.95
- 5222364 1.26 0.05 $16.95
- 5222365 1.3 0.051 $14.35
- 5222367 1.38 0.054 $16.95
- 5222368 1.42 0.056 $16.95

O=Ordered
x=In Stock
-=No stock

Side gear Shim package:
4504 568
We stock all of these.
bust0023 wrote:My car's got some rust on the doors too. Fortunately for me, I don't give a shit.
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UptownSport
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Ford 'S' spring

Postby UptownSport » Fri Dec 17, 2010 11:31 pm

http://www.turbododge.com/forums/f4/f22/133986-8-8-ford-lsd-possible-copy.html

CarltonPowers: This thread will have all the footnotes of the original thread from turbododge.com and neons.org. Information on the installation of this spring and what you can expect once installed will be included.

Why use Ford parts on a neon?
Because it is affordable and and functional. Period. If a Honda intake manifold would bolt up and flowed better than stock, I'd have one. Spare this thread the " I hate fords" comments. Fords has plenty of credentials in the racing scene to back up their stock transmission components.

How does diff mod compare to the Phantom Grip, OBX, and Quaife
It has been stated the 95 mustang diff spring (part # EOAZ-4214-A) performs above the phantom grip. Cost is $11.99 plus tax. Never used of been in a car with the PG, so no comment there. The car does seem to respond more directly to acceleration and launching. Very little spin from my worn tires dropping it from 2k. May try 2500rpm drop at the track. The OBX requires some work to avoid failure. For $500, it should be done before I get it. Seems to work well afterwards though. The Quaife is $1200. That cost more than I paid for my trans, car, seats, etc.. Do not think I'll need such a part for the driving I do. Also heard it makes normal driving a chore, but have nor experienced it first hand to confirm.

http://forums.neons.org/viewtopic.php?t=267937&highlight=obx
http://www.members.aol.com/mopartek/posi_shootout.html

Let's make note of something right now. A LSD is not a free pass to do burn outs without doing any damage to your car. This modification is to increase traction control and limit wheel-spin when launching off the line for better 60ft times. That is about it. This modification cost a whopping $18 including diff tabs from mopar
http://forums.neons.org/viewtopic.php?t ... tial+saver


Image
Here is a pic of what the diff looks like when complete. On the left is the F-150 (part#F3TZ-4214-A) spring in a neon diff( first one done to my knowledge), and the left is the 95 mustang spring.
CarltonPowers:
To date, there have been two failures from those that installed them on their own, and two that have them operating correctly. Of all the diff I did (about 4) are installed in the trans are alive and well :thumbleft:

Here all part numbers associated and installation information will be listed.

7.5" Ford Differential Spring (Ford Part# E4DZ-4214-A)
-This is the smallest diff spring. It can be purchased separately from the entire ford diff assembly. Cost is about $11.99. To install into a neon diff requires a vice of sorts to force the spring into the neon diff. No machine work is required for this installation. This spring was used in the ford SVO mustang, and Ford Ranger. Here is my write for the 7.5" diff spring:

Ghost Neon wrote:Finally had time to get this all done. P You will have to hit the retainer pin from the underside of the diff to remove. You'll see when you have yours out. Took a few whacks, so be patient and careful not to hurt yourself.

Image
Ford part# E4DZ-4514-A Cost $22.50. Ordered in the afternoon and arrived same day. That's nice[/Borat]

Image
Diff from my spare trans out of a 97 5speed stratus. Seems any 5speed or atx the was mated to a neon compatible block will work. The diff is the point of concern
Image
Be sure to remove the plastic speedo gear before removing the dowel pin that holds the diff in place. The diff retainer pin will come in contact with the plastic ring gear if not removed prior. Gently pry it out with a flathead screw driver.

Image
Weapon Of choice. This part all depends on you. Previous comments speak of machining down the spider gears for ease of entry. The upper and lower gears have a bit of a lip there. I saw that as greater holding power under load, so I chose to use some force.

Image
With the table vice being only so long, the diff was inverted. This part was slightly challenging, but is still pretty simple at the same time. Had to hold the diff at an angle to get the S-spring into position. When applying pressure from the table vice, check every few turns to be sure the S-spring is centered. Be sure to allow about an hour to get this done. If the spring is not centerd, it will start to bend when it comes in contact the the spider gear on the side. Use a long sturdy screwdriver, or other prying tool to correct.

Image


Image

This is the finished product.

Cost run down & tools required:
1/8" pin punch - $2.38
12" flat head screw driver
13mm socket
3/8 rachet/breaker bar
claw hammer/mini sledge
table vice
red loc tite
diff saver tabs $5.xx
S-spring =$22.50
[/quote]


8.8" Ford Differential Spring (Ford Part# EOAZ-4214-A)
-This spring the the mid-sized spring. This is the same spring used in the rear differential of the 1989-1995 Supercharged Thunderbird & Mercury Cougar XR7, 1987 Turbo Coupe Thunderbird, and the 1995 mustang GT. All of the following produce 40+ more base horse power, so this part is build to take some power. This installation for the 8.8" spring requires the machining down of the smaller lateral spider gears. The 8.8" spring is taller than the 7.5" spring, and will become wider when compressed into the neon differential. When grinding down the smaller lateral spider gears, take care to keep the surface smooth and even. Check periodically, by installing back in diff, to see if enough material has been removed to clear each side of the 8.8" spring.

F-150 Differential Spring (Ford Part# F3TZ-4214-A)
-This is the largest diff spring found in most Ford trucks. The installation of this spring is similar to the 8.8" spring, though this installation requires the machining of the smaller and larger spider gears. Only one install has been completed, and shipped. Results and performance are unknown at this time. Here is a pic by DJScorpio67 comparing the F-150 spring to the 8.8" spring:
Image

Super8neon also suggested the use of a magnetic drain(part# M14x1.50).
Image
The phantom grip was known for shaving metal either off the spider gears, or itself into the trans fluid. The magnet would be helpful to prevent damage. Get one regardless. The same size can be used for the oil pan.[/img][/quote]
bust0023 wrote:My car's got some rust on the doors too. Fortunately for me, I don't give a shit.
User avatar
UptownSport
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Posts: 1987
Joined: Sun Jul 01, 2007 12:12 pm
Location: Uptown

Re: Differentials

Postby UptownSport » Wed May 02, 2012 11:56 pm

Updated OBX LSD info, as installed another in Doug's car.
It had the same flaws as the last one.
They do work exceedingly well for price.
bust0023 wrote:My car's got some rust on the doors too. Fortunately for me, I don't give a shit.
User avatar
UptownSport
Neon Enthusiast
 
Posts: 1987
Joined: Sun Jul 01, 2007 12:12 pm
Location: Uptown


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