Just FYI for anyone who is rebuilding their differential, the torsen unit in the S2000 cannot be rebuilt. I couldn't find a conclusive answer so I emailed Torsen.

This is their response to my question:
"Unfortunately, we do not offer rebuild kits for any Torsen differential and
the only Torsen differentials we do rebuild are the Frankland Racing and
Ford 9" units."

 

I think Puddydaddys2k would argue with that point. Just because they dont offer a kit doesnt mean it cannot be done.

 

As far as I know Puddydaddys2k uses good leftover parts from other S2k Torsens to replace broken parts.

The bearings can be replaced.
But they are on the outside of the unit.

Even if you're rebuilding a diff (final drive) that went BOOM and parts (metal debris) have been through the Torsen, the units are usually ok as far as I've seen Puddydaddys2k posting.

Using oil that can't handle the pressure may cause the "ears" of the side washers to break off.
Again: as fas as I know even Puddydaddys2k has no OEM Torsen replacements.

Hopefully he will prove me wrong!

 

I just meant the actual Torsen unit cannot be rebuilt. I'm sure it's possible to take it apart and reassemble it with new after market hardware but it's not suppose to be a serviceable unit according to Torsen and the factory manual. It doesn't sound like Torsen sell any of the replacement gears anyway except for the previously units in their email. The manual says: "The Torsen type LSD assembly is a non-serviceable part except the tapered roller bearings. If the Torsen type (LSD) assembly is faulty, it must be replaced as an assembly."

 

It is deemed "non-serviceable" by torsen because they don't sell parts separately to "service" it.


I assure you 100% is is completely rebuildable, if you know what you are doing and can source the parts.