BMW test build

Just for the record, i'm not sure about Grant but I ain't no limp-wristed weenie boy.
Never been beat yet!


Top tips are to make sure the head of the allen or bi-hex bolt is clear of any dirt or debris then tap in the bit to make sure it is engage fully to reduce chances of it rounding off. A Stillson wrench round the driveshaft to stop it turning and jobs a good un..
On a Golf you can use a load of socket extensions joined together and undo the bolts without even going under the car. Then just put a screwdriver in the vents of the disc which can jam against the caliper to stop it rotating.

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Disappointingly not yet a Jackass



Edited 2 time(s). Last edit at 01/11/2013 04:47PM by danster.

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john vanlandingham
Whats a bitch about the CV bolts? I've seen XZN and external Torx, are you just a limp-wristed weenie boy? Might explain the fascination with Bee Ems..

Socket head cap screws or allen or whatever the fawk you wanna call em.

Leaking seals = holes full of grime and shit..
First one we took them off. One person to keep from rotating, break loose with breaker, zip off with cordless impact.
Second one I was alone and figured the two bolts to remove the arm, one support bolt, and one wee little sway bar bolt was easier than breaking all six CV bolts. I was also rushing as the yard was closing since I worked til after 3 and they closed at 5. Less than 90 minutes from time I pulled into parking lot to time I drove out. Putzed around a bit. Probably could do it in 30 minutes with a charge on the 1/2 impact and a buddy. Need to remember cigs next time too.

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Grant Hughes

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danster
Just for the record, i'm not sure about Grant but I ain't no limp-wristed weenie boy.
Never been beat yet!


Top tips are to make sure the head of the allen or bi-hex bolt is clear of any dirt or debris then tap in the bit to make sure it is engage fully to reduce chances of it rounding off. A Stillson wrench round the driveshaft to stop it turning and jobs a good un..
On a Golf you can use a load of socket extensions joined together and undo the bolts without even going under the car. Then just put a screwdriver in the vents of the disc which can jam against the caliper to stop it rotating.

Well Grant is what we call over here a "hipster"...drinks used urine called Pabst Blue Ribbon, rides fixie bikes (One gear, no brakes) or forever it was some little scooter, also known as a 'metro-sexual'

No really a poof but, you know.....

I say yep get those XZN things germ free, then really wail on the the top.
Channel your chi energy and scream like Bruce Lee and wham the bolt hear, then hit it with a 1/2 drive impact gun while pushing in hard so the bit doesn't hop out.

Brutality, but mindful savagery.

That looks like my pile of Sierra halfshafts...

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John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.

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john vanlandingham
Well Grant is what we call over here a "hipster"...drinks used urine called Pabst Blue Ribbon, rides fixie bikes (One gear, no brakes) or forever it was some little scooter, also known as a 'metro-sexual'

When I get pizza I always burn my tongue cause I have to eat it before it's cool. I was building my Merkur before it was cool to have a Merkur project in your garage. Now that everyone's doing it though...

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Grant Hughes

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NoCoast

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john vanlandingham
Well Grant is what we call over here a "hipster"...drinks used urine called Pabst Blue Ribbon, rides fixie bikes (One gear, no brakes) or forever it was some little scooter, also known as a 'metro-sexual'

When I get pizza I always burn my tongue cause I have to eat it before it's cool. I was building my Merkur before it was cool to have a Merkur project in your garage. Now that everyone's doing it though...

So if we extrapolate the formula...you burned your tongue on the Merkur also??

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john vanlandingham
Well Grant is what we call over here a "hipster"... rides fixie bikes....

And there was me thinking he called himself NoCoast because he lived in the centre of the USA, miles from the sea. But it turns out it's because he can't coast on his bike!

Must be something about Colarado that makes them transmission daft, I mean ffs, a LSD on a push bike. I'll bet they put a dab of EP90 gear oil on as aftershave to attract a mate when they go out trying to get laid in their Merkurs too. And when I think back I lost 5th gear on my Civic in the darn place whilst driving around the states in 1989.
But regardless of that, top stuff Grant for posting up all that useful info on crownwheels sizes and ratios. Turns out there is the beginnings of single class series using Bavarian Mook Wagons over here, you will be disgusted to hear on tarmac though.

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Disappointingly not yet a Jackass

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DaveK
Forget shims...is there room to add more plates?
I think guys cut down the shims and add more plates with the Evo diff so they go from 6 to 8 plates.

So, this and Caswell saying to add more clutch plates got me doing a little more research. Here's a nice diagram.



So, the four clutch plate video I found online throws out the "worthless" 4 mm spacer (#7) and machined 4 mm out of the cover (#3) so he could double the clutch plates (#8 and #9).
Made me wonder a few things... Impact on diff's ability due to no longer having the belleville to give any pressure to stuff? Is it simply working on the basis of distance and everything being super tight and barely fitting together?

John mentioned more shims (#5) on the outer face of the Belleville as being an easy way to modify breakaway torque. BMW makes that shim in 1.8 mm to 2.3 mm thickness.
Additionally the outer disc (#8) can be had in 1.9 to 2.1 mm.

Based on the method of machining the cover, wouldn't the side gears no longer be centered and the possibility of a stub shaft sticking too far into the diff be a potential problem?

I would think that the proper way to do it would be to machine 4mm out of the cover and internal of the diff and then add extra plates to add longevity and then fine tune the breakaway torque with the shims at #5. 4 mm out of the internal of the differential would be the tricky one to do.

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Grant Hughes

Those BMW's are sharp lookin cars.

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Kirk Coughlin
Woodbury, MN and River Falls, WI

Quemadmodum gladius neminem occidit, occidentis telum est.

I would think the way to do it would be to look at the part you have and count the plates in the diff and not worry too much about the drawing...

And if you read something that seemed to suggest discarding the bellville spring, I would discard the source you read instead.

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John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.

My thoughts exactly regarding the belleville. Funny thing is in the video he made he was like, this is a spacer so well toss it. I thought, whadafuckryoutinking.
The picture is exactly accurate and better than my pics of the real thing as above.

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Grant Hughes

I'd think that just shimming it to what ever break away JV suggests and call it good. Being it is a rear drive and fairly easy to do (compared to a fwd) even if you had to redo it evry 3 or 4 events not to bad. Being on gravel should be easier on the plates that are there anyway and with less slippage they should last longer?

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NoCoast
My thoughts exactly regarding the belleville. Funny thing is in the video he made he was like, this is a spacer so well toss it. I thought, whadafuckryoutinking.
The picture is exactly accurate and better than my pics of the real thing as above.

So there's really only one disc and one plate per side?
I bought one of those from good ol Holland's Auto Wrecking years ago just to strip down and measure everything with evil intent cause its the same design like any good LSD andbeing it's the same ZF diff "family" as the ZF Ford used as the low cost alternate to the Sierra 9", and same as Portch 911, and same as what Volvo used in Group A roadracing (it's called "006" family---somewhere there should be stamped in the case ZF's part number, a typical Krautski 15 digit thing like xxxx xxx 006 xxxx xxx), I figured it would be big enough to examine for Xratty use...

Memory says there were more discs than one driven one driving per side...
Like 3 each/side.

My little Saab has 2 each/side or 4 total+ belleville +shims..

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John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.

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NoCoast
A little short on plates. Belleville washer, steel disc, and friction plate. That's it on this side. Didn't dig in to see if other side is the same.

Yeah, here is the pic of it again.

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Grant Hughes

Ha. Okay, so looks like there may be a 4 mm spacer in the bottom of the diff and dude wasn't just removing the washers. You can see it right up front in this picture...



So remove that spacer, machine 4 mm off the cover plate and you have 8 mm of space for 4 more plates.

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Grant Hughes

That makes much more sense.