My new ready-to-install diff (comptech housing & 4.57s already installed) showed up on Friday -- thanks, Stratocaster!!!!

The removal process wasn't that bad, save for a couple of stubborn bolts. I really wish there was such a thing as an impact wrench with a 90-degree adapter. Lots of the bolts that have to come off are TIGHT, and there's not enough room to get an impact wrench anywhere near them. My chest and arm's are sore already.

With the car up on stands and the wheels remove, unbolt the ABS sensor bracket from the upper control arm:



Unbolt the upper control arm from the subframe and let the lower control arm droop a bit. Support it with a jackstand or something to give the brake line some slack.


Remove the 6 bolts from the inner CV joint and separate it from the diff. Push the axel to the back of the diff and set it on the subframe.


Remove the 6 allen bolts that connect the driveshaft to the diff. This is where I ran into problems. I stripped 2 of the allen sockets.


Now I was stuck -- how am I going to get these screws out, while I'm laying on my back under the car... I know, I'll unbolt the driveshaft from the tranny, pull the whole thing out, go to dinner and deal with it later.


Diff and driveshaft are OUT!!!


Now, after dinner, I tried to get those stripped bolts out. I tried a hammer, bigger allen keys, torx bits, damaged screw removers, wreches, bigger hammers, but this is all I got:


Then, I tried drilling:


I decided I needed reinforcements, so I ran to wal-mart and picked up one of these babies:


Take that, you little bastard!


and that:


oh, take that too:


mmmuhahaha!!! I win!!!


The diff and driveshaft are now parted!


I was super lucky that I thought ahead and bought TWO extra driveshaft bolts on Saturday. Tomorrow, the new diff goes in. Hopefully I can get that done by lunchtime, as I still have to rebuild my front calipers, install the braided brake hoses, and finish installing my cooling ducts. If I get all that done tomorrow, it will be a miracle.

 

With them grooved edges, I would think a big pair of channel locks would've done the trick? Certainly not as fun as buying a new tool though... good decision!

Things are lookin' good! I can't wait to go for a ride next Saturday!

 

should of used toptul

how much did all this cost? im still planning the 4.44 kit. too many people have said the 4.57 was noisy but you can be the guinea pig

 

$2400 and I get $1000 back for the core exchange when I ship them my stock diff back. I'll trade a little diff whine for strength anyday.

Toptul needs to have a 'try before you buy' program!

 

Great post. Thanks!

Any more progress? What about the yellow box?

What are you going to do differently when you swap out mine?

 

hey SC Highlander, ive been dying to hear about the Elise? Did you get it? If you did, I cant wait to see pictures!

 

The new diff went in surprisingly easy, although getting those rearward upper control arm bolts back in was a BITCH. I had to jack up the suspension to compress the spring, then umm... persuade the bolts a bit. I still have to torque down the bolts on the inner CV's and reinstall the driveshaft, but she should be back on the ground tomorrow night. If I had to do it again, I might do as the book suggests, and pop the lower ball joints instead of pulling the upper suspension arm...

I also rebuilt my front calipers, installed braided stainless brake hoses, and worked on my brake cooling ducts today, so I'm whipped.

I got Modifry's yellow jacket for the speedometer correction . It is only 4 connections under the driver's dash beside the ECU. I'll install that one day this week.

As long as I get some time to recover before I tackle yours, I'd be happy to do it, Ron. I did mine at a very leisurely pace -- including brakes to watch the indy 500, meals, etc. I'd say, excluding the stripped bolt removal, I've spent about 5 hours so far with another hour left to go. It's sickening, because Jeff (Hardtopguy) says his guys can pull a diff in about 30 minutes!

 

I decided to keep the S, and did not buy the Elise.

 

Thats cool, im actually glad to see you still have the S, although i really wanted to see the Elise up close and personal at a meet...

My cousin who is 2 inches shorter than I, and I'm 6'3", said he couldnt fit in it.

But glad to see you kept the S!

 

Vise Grips would have been e-x-t-r-e-m-e-l-y handy for those stripped bolts. Not necessarily the lil' bitty pair that this young lady is holding...but you get the idea .

Oh, and Bryan ...glad you passed on the Elise my friend. Not that its a bad car, its great I'm sure. But as you're funnin' now, you can do soooooo much to your Suzuka with the money you save . Sounds like some super mods! .

- Dave

PS. Sheila...? You get all these instructions down for our "late night raid" on Ron's NFR?