Junkyard Special Kia 4.77 ring & pinion install
03-07-2007, 10:08 AM
#32
Registered User
Thread Starter
Join Date: Aug 2005
Location: Richmond, IN
Posts: 406
Likes: 0
Received 0 Likes
on
0 Posts
Originally Posted by SpitfireS,Mar 7 2007, 01:45 AM
300sx Posted on Mar 7 2007, 02:15 AM
The extra caps are just that: extra caps.
I do not recall they were threaded anywhere (apart from the locking screw thread on top)
The EOM bearing caps do not have the mounting surafce to do that.
IMO you have to machine those mounting surfaces on the OEM cap to get the proper "help" from the extra cap.
If there is room between them, then the OEM cap may still flex and thats the start of final drive damage.
Get yourself a S2000 service manual before attempting to work on your S2000 diff.
Please!
The extra caps are just that: extra caps.
I do not recall they were threaded anywhere (apart from the locking screw thread on top)
The EOM bearing caps do not have the mounting surafce to do that.
IMO you have to machine those mounting surfaces on the OEM cap to get the proper "help" from the extra cap.
If there is room between them, then the OEM cap may still flex and thats the start of final drive damage.
Get yourself a S2000 service manual before attempting to work on your S2000 diff.
Please!
03-07-2007, 11:28 AM
#33
Registered User
Join Date: Jan 2006
Location: 17 ft below sea level.
Posts: 4,949
Likes: 0
Received 21 Likes
on
16 Posts
300sx Posted on Mar 7 2007, 08:08 PM
Simple answer : No, that is not possible.
As soon as the hole is machined where the Torsen bearings go (in 1 setup) the bearing cap & the side its mounted on becomes a "set", one diff housing has 2 bearing caps, that makes 2 "sets" and they are married for life with that particular diff housing, one cap mounted on one side, one on the other side and it should stay that way, no divorce or swap possible.
The thread (for the adjuster ring) makes it extra impossible.
Get well soon
I was thinking of a way to ditch the stock caps all together but like I said I have yet to tear either diff apart more than pictured so I don't know if this is possible.
As soon as the hole is machined where the Torsen bearings go (in 1 setup) the bearing cap & the side its mounted on becomes a "set", one diff housing has 2 bearing caps, that makes 2 "sets" and they are married for life with that particular diff housing, one cap mounted on one side, one on the other side and it should stay that way, no divorce or swap possible.
The thread (for the adjuster ring) makes it extra impossible.
Get well soon
03-08-2007, 06:45 PM
#34
Registered User
Join Date: Jul 2006
Location: West Hollywood, CA
Posts: 388
Likes: 0
Received 0 Likes
on
0 Posts
[QUOTE=300sx,Mar 7 2007, 11:08 AM]I think you misunderstood me, I was referring to the stock caps being threaded, not the Comptech "secondary" caps. I was thinking of a way to ditch the stock caps all together but like I said I have yet to tear either diff apart more than pictured so I don't know if this is possible. Won't be able to mess with it today, I decided to get some sort of stomach flu instead
03-09-2007, 02:18 AM
#35
Registered User
Join Date: Mar 2004
Location: Slovakian living in Dubai
Posts: 2,976
Likes: 0
Received 1 Like
on
1 Post
Originally Posted by kill,Mar 5 2007, 07:03 PM
if you reinstall them into another diff they have to be broken in again...or else you could blow them up...everytime you remove them they have to be meshed correctly...and they need to go through a brake in process...
) and went straigth to the drag strip to brake them in 
Are the 4.77 from an automatic or manual Kia SPortage? Both have different spare part numbers.
03-09-2007, 02:21 AM
#36
Registered User
Join Date: Mar 2004
Location: Slovakian living in Dubai
Posts: 2,976
Likes: 0
Received 1 Like
on
1 Post
Originally Posted by SpitfireS,Mar 8 2007, 12:28 AM
300sx Posted on Mar 7 2007, 08:08 PM
Simple answer : No, that is not possible.
As soon as the hole is machined where the Torsen bearings go (in 1 setup) the bearing cap & the side its mounted on becomes a "set", one diff housing has 2 bearing caps, that makes 2 "sets" and they are married for life with that particular diff housing, one cap mounted on one side, one on the other side and it should stay that way, no divorce or swap possible.
The thread (for the adjuster ring) makes it extra impossible.
Get well soon
Simple answer : No, that is not possible.
As soon as the hole is machined where the Torsen bearings go (in 1 setup) the bearing cap & the side its mounted on becomes a "set", one diff housing has 2 bearing caps, that makes 2 "sets" and they are married for life with that particular diff housing, one cap mounted on one side, one on the other side and it should stay that way, no divorce or swap possible.
The thread (for the adjuster ring) makes it extra impossible.
Get well soon
03-09-2007, 03:24 AM
#37
Registered User
Join Date: Jan 2006
Location: 17 ft below sea level.
Posts: 4,949
Likes: 0
Received 21 Likes
on
16 Posts
jakub2000 Posted on Mar 9 2007, 12:21 PM
Impressive
Did they use the original (OEM) bearing size?
Because if you can find a conical bearing with the same inner diameter (for the Torsen housing), not that much wider (or the same width) with a bigger outside diameter one could make complete new "holes" and thread them.
It takes only 1-2 mm in outside diameter to be able do that IMO.
That involves making new locking rings too.
I'll bet they spend 4 out of the 5 days lining your diff housing up on a milling machine
Even more important: Did you take pictures?
You would not believe it but a local machine shop managed to manufacture new caps for me that matched the thread. (stock ones gave up under 400whp ) took them a week and 250USD. But the guy told me I will brake anything before those caps give up.
Did they use the original (OEM) bearing size?
Because if you can find a conical bearing with the same inner diameter (for the Torsen housing), not that much wider (or the same width) with a bigger outside diameter one could make complete new "holes" and thread them.
It takes only 1-2 mm in outside diameter to be able do that IMO.
That involves making new locking rings too.
I'll bet they spend 4 out of the 5 days lining your diff housing up on a milling machine
Even more important: Did you take pictures?
03-10-2007, 10:26 AM
#38
Registered User
Thread Starter
Join Date: Aug 2005
Location: Richmond, IN
Posts: 406
Likes: 0
Received 0 Likes
on
0 Posts
Originally Posted by SilentWhiteNoise,Mar 8 2007, 07:45 PM
Can't you just take a bucket with you to work on the car? I can just see it now....
1. Remove Diff from s2k
2.
3. Open s2k Diff
4.
5. Open Kia Diff
6.
7. Swap Diff
8.
9. Reinstall Diff in S2k
10. Take pride in the work you have done (while barfing)
11.
12. Back in house
13. 
1. Remove Diff from s2k
2.
3. Open s2k Diff
4.
5. Open Kia Diff
6.
7. Swap Diff
8.
9. Reinstall Diff in S2k
10. Take pri
de in the work you have done (while barfing)11.
12. Back in house
13.
. I'm finally going to get back in the garage tomorrow, I promise lol!
03-15-2007, 07:35 AM
#40
Registered User
Join Date: Mar 2004
Location: Slovakian living in Dubai
Posts: 2,976
Likes: 0
Received 1 Like
on
1 Post
Originally Posted by SpitfireS' date='Mar 9 2007, 04:24 PM
jakub2000 Posted on Mar 9 2007, 12:21 PM
Impressive
Did they use the original (OEM) bearing size?
Because if you can find a conical bearing with the same inner diameter (for the Torsen housing), not that much wider (or the same width) with a bigger outside diameter one could make complete new "holes" and thread them.
It takes only 1-2 mm in outside diameter to be able do that IMO.
That involves making new locking rings too.
I'll bet they spend 4 out of the 5 days lining your diff housing up on a milling machine
Even more important: Did you take pictures?
Impressive
Did they use the original (OEM) bearing size?
Because if you can find a conical bearing with the same inner diameter (for the Torsen housing), not that much wider (or the same width) with a bigger outside diameter one could make complete new "holes" and thread them.
It takes only 1-2 mm in outside diameter to be able do that IMO.
That involves making new locking rings too.
I'll bet they spend 4 out of the 5 days lining your diff housing up on a milling machine
Even more important: Did you take pictures?
Yes I took pictures, but since I am not working at the moment (till April) I will have to find a place to post.
The biggest challange was for them to match the thread, we re-used the stock bearings. Keep in mind that the stock part is threaded first, than cut into 2 pieces. They had to create a new bearing cap and match the thread. 2 days of calculation were involved, so far it holds up (420whp and Exedy Hyper Single)
I need to know for a friend of mine, are the Kia gears manual or automatic????