I posted this in the Under the Hood section but I figured I would share it with others who might be interested in this project.

So I picked up a AP1 differential for cheap price knowing that it was probably blown (seller is a Honda mechanic and removed it from some kid's S2000 after he blew it). All he knew was that it would 'lock up' apparently. I figured the price was so low that it would be worth the investment and tackling on learning how to rebuild a differential and possibly throwing this one on my S2000. Worse case scenario is I would have a bunch of parts as paper weights and stuff to display in my office.

First thing is first... I try to drain it and found this stuck on the magnetic drain plug...



Yikes... Not a good sign...

I pop off the output shafts...





I remove the differential case and clean up some of the oil...



I start finding more metal chunks... not shavings or pieces... CHUNKS



I can already see the pinon is heavily damaged...



I proceed to mark the bearing caps and adjustment screws on both sides



Not sure if this is a normal but one cap looks like it might have shifted...



One of the lock plates looks like it has shifted too...



Bearing caps off...



More chunks from the pinon...





LSD + ring gear...



Using an impact gun, I removed the locknut



The companion flange popped off using a puller



Drive pinon out...



More chunks...



Pinon totally trashed...





Ring gear damaged



I had to stop to BBQ for dinner but this will be a part time project... If it's salvageable, I might plan on getting a Kia 4.77 gear + pinon... I'll have to replace various seals, spacer, clips, washers anyhow... I'm reaching out to the S2Ki.com community for their thought and input... more updates as I make more progress...

*****Update*****

Bought $150 in parts to replace the oil seals, bearings, cups, nut and pinion spacer.



New axle oil seals


Used a socket + mallet to press into place:


Finished product


Baffle back into place with some lock tight

 

I wouldnt try to do that myself, its cool you are doing it urself!

 

damn , that thing blew up

 

what a project!

 

very cool, and nice pictures! i'm learning just from this thread! thanks!!

 

wow that looks like alot of work, i would not know how to take those things apart

 

whats with the kia parts?

 

[QUOTE=turbomagazine.com]Honda sourced the Mazda 7-inch rear for the Honda S2000. This doesn't necessarily mean you can simply bolt a Mazda rear end on your S2K and call it a day because of the difference in rear housing and axel designs. It seems Mazda has been sourcing out its gears to Honda S2Ks and '94-'02 Kia Sportages 4x4. The front axle of the Sportage has a Mazda 4.778 ring and pinion (part number MM05727110), which high-performance retailers have been secretly selling as an aftermarket gear for over $1,000. The only difference between the $1,000 unit and the $267.93 gear set we bought is, of course, the price gouging and the possibility of a few retailers who add cryogenic treatment to the units as a bonus. The same 4.77 final gear set found in the Kia is interchangeable to fit on the S2K as a direct bolt on, as well as the Mazda final drive off a stock RX-8 with a 4.44 ratio. Upon further research, we found numerous final drive setups that were all interchangeable between the S2K and Mazda, including a n/a powered S2K's dream come true 4.625 ratio, which is available on the New Zealand Kia Sportage. When comparing the S2K factory 4.1-ratio final drive to the 4.77 final installed in our factory pumpkin, we found numerous pros and cons attributed with this setup.

Vehicle Year/Model

 

Same exact thing happened to me




Not a good sign








Now thats a souvenir!

 

i'm too chicken to tackle a job like that, kudos to you