Differential issue - extreme huge trouble

[MartinS]

Hi folks!

Last year in november i decided to rebuild my rearaxle assembly to the fullst. I bought a new Cusco RS 2way differential and a Weirperformance 4.7 Kit. All the small parts included It was around 2000€+. Wheel bearings, brakelines, new calipers, new discs, gasket kit, etc. Really I like to do thinks clean and nice!



We bolted the axle to my car around end of february, with a new Pass Racing one piece drive shaft. Very soon some isues started. After the first 500km the shit became in credibly loud. And the differential was leaking through the pinion seal.

I decided to take it to my mechanic who did the alignement on the differential. He is experienced and working for Toyota since more than 20years. He's a true hachiroku mechanic.

We analysized the problem an thought that the pinion seal was leaking, because of the driveshaft which was too long, as we thougt. (My car is pretty low with the current setup maybe 70mm+). We replaced the driveshaft with the original one, did a pumpkin rebuild with a new gasket and a new set of pinion bearings. Then I drove home and went to my first trackday this season. The car was louder, but did a good job. Until i arrived at home, the play in the rearend became noticibly bigger.

I left the car in the garage and didn't take it out for a ride for about 2 - 3 weeks and then i decided to redo the whole story. I put the car on jacks in my garage and took down the differential assembly. I thought this time I'm going the safe route. I took the differential to a place 150km away from my house to a real hachiroku maniak. (They built some really fast AE86 hillclimb cars and engines with 220hp+). I really new the guy was doing a grate job and his reputation was more then worth a shot.

Friday I finaly got the differential back home. I had a chat with him and he said the pinion and crown has some marks of missalignment, he did a few tweaks there and here and it should be good. Maybe it's a bit noisier then a std. but till winter it will be more than good and no problems driving it on daily basis. I was really confident, that this time the shit will come to an end. I put so much energy and passion in this rearend, that it had to come to an end.

Saturday we went playing poker with a friend of mine and came back at 0230. We decided that we bolt the diff to the car as i couldn't sleep. 0500 I was finally in bed. I couldn't do a testdrive at night, as i was still a bit tipsy from the poker session.

Today I got up in the morning turned over the car and did maybe 300m. It's a +"*ç%&/()ç*%*"*ç&"&%R/& bullshit isue. The noise is still here and nobody knows why. I'm really finished I don't see any other solution then selling my car or to push it into a river!

If somebody has an idea, hint, feel free to post it here.

Cheers