Diff swap help
 

Hey guys. I am swapping out my rear diff to another stock diff that has had a 4.5 final drive pre-installed. Need some help.

1. How do the axles come free of the diff carrier? It looks like you just unbolt the carrier and lower it down and they slide out. Not sure if I have to take any rear suspention apart here. Do I have to disconnect the axles at the rear hubs?

2. I have all the tourqe values I need except the bolts that connect the differential and axle. Looks like a dozen or so small black bolts. Anyone have the tourqe values on those?

3. Will I need to remove the mid-pipe for this install?

4. Will I need to pull out the drive shaft? Tourqe specs anyone?

If anyone has any advice it would be most appreciated. A general step by step would make my day! I am sure I can figure it out, but it will go much smoother if some of you can chime in with some info. Car is up in the air now. Trying to get this done over the weekend.

Have you tried the Scion FRS Repair Manual that you can download from this site? Diff removal and specs start on page 241.

1/2: Rear drive axles appear to be held in by a snap ring of some kind according to the manual; undo the snap rings and lower the differential carefully.

3: In order to remove the driveshaft/prop shaft you will need to remove the midpipe, or that's what the manual would have you believe. See picture below.

4: Manual calls for removal of the driveshaft/prop shaft BEFORE removal of the diff; you may be able to support it and simply remove the bolts that secure it to the differential. Driveshaft/prop shaft is held to the differential with 4 bolts torqued to 55ft-lbs. Note that the manual uses SST to keep oil in the diff. It seems entirely removing the diff would not be the best idea on your driveway.

See RaceComp's picture:
https://sphotos-b.xx.fbcdn.net/hphot...54352268_o.jpg

With their exhaust they didn't have to remove their midpipe (looks like PART of it is removed), but with a stock location flange exhaust you would have to remove the midpipe. Looks like they do the smart thing and keep the driveshaft in as well.

Thanks guys! I'll toy with it a bit tonight. Let me know if anyone has anything else to add.

Got the mid pipe down and the drive shaft separated from the diff carrier. I unbolted the two bolts that hold the joint in the middle of the driveshaft to the chassis. Anyone have tightening specs on those for when I put it back together?

38lbs.

Hit a snag.

I got the diff unbolted and supported by a jack. I disconnected the dust boots and started to lower the diff thinking the axles would slide out but they didn't. The diff lowered all the way to the ground with the axles still in. I am worried about messing up my axles at this point.

It seems maybe I need the car to be a bit higher? Or maybe drop the diff to the ground and lift the back of the car up until the axles drop out?

Am I going about getting the axles out correctly or am i missing something? I'm so close!

Prybar. Sounds barbaric, but the SST is just a prybar.

But what am I prying? Do I pry the diff carrier to one side to get one axle out and then just slide it off the other side? Or do I lift the car and pry down in the carrier?

Also, your the man! Midnight mechanic hotline!

See my edit, I added a pic right out of the manual. The axle stub that was in the diff should come out with a clip on it...that's what you're fighting against. Don't remove it from the axle stub after you pull the axle out.

Tried to do it with a big screw driver but didn't work. Going to have to buy a pry bar and try it again tomorrow. Reinstalled the dust boot clips.

Thanks again. I'll keep you posted.

Did you try bracing the screwdriver against the diff? I'd just be careful not to mar the diff housing; try leveraging the prybar/screwdriver over a bolt head if possible.

Good luck.

I did try to leverage against the carrier. Just couldn't get it. A bigger bar should do the trick. I have a very busy day tomorrow but I am hoping to at least get the old diff out. Sunday I hope to get the new carrier, whiteline bushings, shifter bushing, and shift springs all installed. Once I get the diff out I think it will all go easy. Thank you once again.

No problemo, hope I was semi-helpful.