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Resolved Need rear diff help!

Posted by Steve92talon, Oct 24, 2019

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  1. Steve92talon

    Steve92talon Proven Member

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    My clutches smell horrible in my rear dif . I have a J1H 3.307 4 bolt axel and the spare diff my car came with is a B17 3.545 3 bolt axel. Can I swap them or am I screwed rebuilding the J1H diff. I have my car torn apart some speedy replies is much appreciated manual turbo 5 speed 92.
     
  2. Mello

    Mello Proven Member

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    I may be wrong but I don't think DSM's came with clutches in the rear diff, only viscous couples. What makes you think it's the clutches. Have you check and or change the rear diff fluid?
     
  3. Steve92talon

    Steve92talon Proven Member

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    The smell is horrible soon as I drained the fluid. Yes I serviced it about 10k ago with fresh fluid. I actually think I have a mismatched transmission, transfercase, rear end ratio making the rear burn itself up turning the wrong speed. My other transmission and transfer case have the smaller output shaft so I cant swap the good transfercase on this transmission.
     
  4. 91talonts1

    91talonts1 Proven Member

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    Are you getting a burning smell when the diff is warmed up or something? Or the fluid just stinks?Gear oil smells terrible new, it smells even worse once it's used. It has sulphur in it.
     
    Last edited: Oct 24, 2019

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  5. DSMPT

    DSMPT Proven Member

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    IMO you burnt the VC. It's because you are using an auto 3.307 rear diff on a manual car, unless the rear diff ring gear has been swapped with the manual one.
     

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  6. Steve92talon

    Steve92talon Proven Member

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    I thought the vc was built into the transmission not the rear end?
     
  7. Steve92talon

    Steve92talon Proven Member

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    Can I swap anything over from the 3 bolt rear end I have. I can see the axels are bigger on the 4 bolt so I can't put the 3 bolt in my car with 4 bolt axels.
     
  8. Steve92talon

    Steve92talon Proven Member

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    I was under the impression the viscous coupler was in the transmission between the transfer case output shaft and the front axel output. Under the side cover on the passenger side.
    I thought the viscous coupler was built into the transmission under the side cover where the output shaft hooks up....???
     
  9. Mello

    Mello Proven Member

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    AWD has a VC on the center diff. If you have a LSD then there's a VC in the rear diff too. Not all AWD have a LSD rear diff. The LSD rear was an option. If you've been running an auto diff on a manual I would be concerned on the condition of the center diff too.
     
    steve likes this.
  10. DSMPT

    DSMPT Proven Member

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  11. Steve92talon

    Steve92talon Proven Member

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    Sorry I am new to all these terms and a rookie with dsm. When u say center diff u mean inside the transmission?
     
  12. 1990TSIAWDTALON

    1990TSIAWDTALON Moderator

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    Yes
     

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  13. Steve92talon

    Steve92talon Proven Member

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    Well I have a spare center diff in the other trans. Do any parts interchange between the 3 bolt and 4 bolt. Like the gears to correct the ratio. I looked through this whole section I dident see what my correct rear gear is supposed to be for a 92 with a 91+ transmission. I read I can swap the output shaft to fit the 90 transfercase i have.
     
  14. OH91awd

    OH91awd Proven Member

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    ring and pinion will swap over. i would defiently suggest you getting the auto ring and pinion out of there that is going to destroy things since youre a 5spd.
     

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  15. DSMPT

    DSMPT Proven Member

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    Probably just swapping the rear ring gear doesn't work for your case. because it seems you already destroyed something in the rear diff. Also you will need more work to swap the parts you need, like the process in the link I put above.
    I think just look for a good manual 3.545 4 bolt rear diff or replace the rear end with your spare 3 bolt. That would be the easiest way for you..
     

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  16. Steve92talon

    Steve92talon Proven Member

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    The 3 bolt won't just bomt in though I will need the replace the axel hubs correct? I was thinking if I could swap in the guts of the 3 bolt to the 4 bolt maybe. But I know the bearings and axels are different sizes from doing some measuring. I will rip both diffs apart tonight see what I have and read that article in more detail
     
  17. OH91awd

    OH91awd Proven Member

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    @jersygsx just posted one for sale as well if its needed.
     

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  18. OH91awd

    OH91awd Proven Member

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    wont be able to bolt the differential out of the 3 bolt in. theyre different. only thing that interchanges between 3 bolt and 4 bolt is the ring and pinion.
     

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  19. Steve92talon

    Steve92talon Proven Member

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    That's ok though my bearings spin smooth and if I just need to swap the gears and weld up the spider gears to be back on the road in awd bonus.
     
  20. Steve92talon

    Steve92talon Proven Member

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    I'm in British Columbia canAda though
     
  21. OH91awd

    OH91awd Proven Member

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    just an option. these things are getting hard to come by.
     

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  22. DSMPT

    DSMPT Proven Member

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    Correct. Axles, cups, too.
     

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  23. Steve92talon

    Steve92talon Proven Member

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    Rebuilt it with the right 3.545 gears with .004 backlash. Tomorrow I will bolt my car back together after I swap the output shaft and the center diff possibly from the 90 spare trans. Hopefully this will work for me to get back on the road. If the vc is smoked and it's just a open diff least it's still functional for now.
     

    Attached Files:

  24. Steve92talon

    Steve92talon Proven Member

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    600km trip this weekend to go see my kid went very well. Checked my fluids after I got back and it's all looking great. Thanks for the tips and help getting my gearing fixed and back on the road I'm pretty sure both vc are toast from heat but that's for latter down the road. Maybe after winter is over and I can spend time with it off the road while I drive my cordoba.
     

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