Test and Reviews

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STEP 1

Front differential - Rear differential - Center differential

Front differential

	According to the manual we start with building the differentials. So we take bag 01.1 and open it.
	Put all parts from this bag in a glass bowl or on a dinner plate.
	Take the differential housing and put a 8 x 16 x 5 mm bearing on the differential output.
	Take the differential shaft and place at the red spot some heavy duty high temp grease (not included in the kit). The manual advises to put some oil on this spot! Slide the differential shaft fully into the differential housing.
	Put a 6 x 1.5 mm O-ring on the shaft by hand.
	Take a sun gear and place it upside down on the shaft and gently press and turn the O-ring into the differential housing. Take out the sun gear!
	Take a 6 x 18 x 0.2 mm washer and place it on the shaft.
	Slide with a small pliers a 2 x 11.6 mm pin trough the hole of the shaft and make it even at both sides.
	Place the sun gear with the teeth upwards and make it fall over the pin in the shaft.
	Take the 40 T gear and put a 8 x 16 x 5 mm bearing on the differential output.
	Take the differential shaft and place at the red spot some heavy duty high temp grease (not included in the kit). The manual advises to put some oil on this spot! Slide the differential shaft fully into the differential housing.
	Put a 6 x 1.5 mm O-ring on the shaft by hand.
	Take a sun gear and place it upside down on the shaft and gently press and turn the O-ring into the differential housing. Take out the sun gear!
	Take a 6 x 18 x 0.2 mm washer and place it on the shaft.
	Slide with a small pliers a 2 x 11.6 mm pin trough the hole of the shaft and make it even at both sides.
	Place the gasket in the gear and align the mounting holes.
	Take a gear shaft and put at each side a satellite gear and a 3.5 x 12 x 0.2 mm washer. Make two of these shafts.
	The manual advise to put in each satellite gear a 3 x 1.5 mm O-ring. We know from experience that this O-ring makes the differential work inconsistent so we do not mount them.
	Place the first shaft with the satellite gears in the differential housing. Put the cut out of the shaft facing upwards.
	Place the second shaft with the satellite gears in the differential housing. Put the cut out of the shaft facing downwards.
	The kit comes with a bottle of silicone oil of 7.000 Cps for the front differential. Take care that the printing on the bottle is real quickly vanished so mark it with a good marker felt pen.
	Fill the differential until the fluid level is just on top of the satellite gear shafts
	The manual advises to fill the differential for 80% but how much is 80%? Therefore  we advise to fill as mentioned above.
	Place the sun gear with the teeth facing down.
	Take the gear and align the pin of the shaft and the sun gear. Align the holes in the differential housing and the gear.
	Place the 3 x 12 mm counter sunk hexagon screws using a 2 mm hexagon tool. Turn them one by one until they almost are tight. Tight the last 3 turns of the screws in a cross pattern. Do not over tight..
	The front differential ready.

Rear differential

	We know build the rear differential. So we take bag 01.2 and open it.
	Take the differential housing and put a 8 x 16 x 5 mm bearing on the differential output.
	Take the differential shaft and place at the red spot some heavy duty high temp grease (not included in the kit). The manual advises to put some oil on this spot! Slide the differential shaft fully into the differential housing.
	Put a 6 x 1.5 mm O-ring on the shaft by hand.
	Take a sun gear and place it upside down on the shaft and gently press and turn the O-ring into the differential housing. Take out the sun gear!
	Take a 6 x 18 x 0.2 mm washer and place it on the shaft.
	Slide with a small pliers a  2 x 11.6 mm pin trough the hole of the shaft and make it even at both sides.
	Place the sun gear with the teeth upwards and make it fall over the pin in the shaft.
	Take the 40 T gear and put a 8 x 16 x 5 mm bearing on the differential output.
	Take the differential shaft and place at the red spot some heavy duty high temp grease (not included in the kit). The manual advises to put some oil on this spot! Slide the differential shaft fully into the differential housing.
	Put a 6 x 1.5 mm O-ring on the shaft by hand.
	Take a sun gear and place it upside down on the shaft and gently press and turn the O-ring into the differential housing. Take out the sun gear!
	Take a 6 x 18 x 0.2 mm washer and place it on the shaft.
	Slide with a small pliers a 2 x 11.6 mm pin trough the hole of the shaft and make it even at both sides.
	Place the gasket in the gear and align the mounting holes.
	Take a gear shaft and put at each side a satellite gear and a 3.5 x 12 x 0.2 mm washer. Make two of these shafts.
	Place the first shaft with the satellite gears in the differential housing. Put the cut out of the shaft facing upwards.
	Place the second shaft with the satellite gears in the differential housing. Put the cut out of the shaft facing downwards.
	The kit comes with a bottle of silicone oil of 1.000 Cps for the rear differential. Take care that the printing on the bottle is real quickly vanished so mark it with a good marker felt pen.
	Fill the differential until the fluid level is just on top of the satellite gear shafts
	The manual advises to fill the differential for 80% but how much is 80%? Therefore  we advise to fill as mentioned above.
	Place the sun gear with the teeth facing down.
	Take the gear and align the pin of the shaft and the sun gear. Align the holes in the differential housing and the gear.
	Place the 3 x 12 mm counter sunk hexagon screws using a 2 mm hexagon tool. Turn them one by one until they almost are tight. Tight the last 3 turns of the screws in a cross pattern. Do not over tight..
	The rear differential ready.
	Both front and rear differentials ready.

Center differential

	We know build the rear differential. So we take bag 1.3 and open it.
	Take the differential housing and put a 8 x 16 x 5 mm bearing on the differential output.
	Take the differential shaft and place at the red spot some heavy duty high temp grease (not included in the kit). The manual advises to put some oil on this spot! Slide the differential shaft fully into the differential housing.
	Put a 6 x 1.5 mm O-ring on the shaft by hand.
	Take a sun gear and place it upside down on the shaft and gently press and turn the O-ring into the differential housing. Take out the sun gear!
	Take a 6 x 18 x 0.2 mm washer and place it on the shaft.
	Slide with a small pliers 2 x 11.6 mm pin trough the hole of the shaft and make it even at both sides.
	Place the sun gear with the teeth upwards and make it fall over the pin in the shaft.
	Take the 46 T gear and put a 8 x 16 x 5 mm bearing on the differential output.
	Take the differential shaft and place at the red spot some heavy duty high temp grease (not included in the kit). The manual advises to put some oil on this spot! Slide the differential shaft fully into the differential housing.
	Put a 6 x 1.5 mm O-ring on the shaft by hand.
	Take a sun gear and place it upside down on the shaft and gently press and turn the O-ring into the differential housing. Take off the sun gear!
	Take a 6 x 18 x 0.2 mm washer and place it on the shaft.
	Slide with a small pliers 2 x 11.6 mm pin trough the hole of the shaft and make it even at both sides.
	Place the gasket in the gear and align the mounting holes.
	Take a gear shaft and put at each side a satellite gear and a 3.5 x 12 x 0.2 mm washer. Make two of these shafts.
	The manual advise to put in each satellite gear a 3 x 1.5 mm O-ring. We know from experience that this O-ring makes the differential work inconsistent so we do not mount them.
	Place the first shaft with the satellite gears in the differential housing. Put the cut out of the shaft facing upwards.
	Place the second shaft with the satellite gears in the differential housing. Put the cut out of the shaft facing downwards.
	We use the bottle of silicone oil of 7.000 Cps that is also used for the center differential according to the standard set up sheet that comes with the car. The manual itself does not mention a specific value but advises a value between 5.000 and 10.000 Cps
	Fill the differential until the fluid level is just on top of the satellite gear shafts
	The manual advises to fill the differential for 80% but how much is 80%? Therefore  we advise to fill as mentioned above.
	Place the sun gear with the teeth facing down.
	Take the gear and align the pin of the shaft and the sun gear. Align the holes in the differential housing and the gear.
	Place the 3 x 12 mm counter sunk hexagon screws using a 2 mm hexagon tool. Turn them one by one until they almost are tight. Tight the last 3 turns of the screws in a cross pattern. Do not over tight..
	The center  differential ready.
	The differentials are of superb quality and have no high notches while turned when new. Also the correct silicone oil is a nice feature. As said we do not use the small O-rings in the satellite gears.
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