| Size |
Caption |
| 148538 |
There's the dead diff. Gotta get all the stuff out of the way to pull it. |
| 94131 |
12psi + lead foot + 1.6L diff = metal magnet toy for a diff drain plug! |
| 132156 |
If you have an aftermarket brace, make sure you mark the alignment cam before unbolting it! |
| 132645 |
Yours won't look like this, but it will be similar. Make sure you use penetrating lube the night before on the rear cat studs. Remove the exhaust. |
| 143291 |
I used some cable ties to hold the cat up. I didn't want the turbo holding the entire downpipe and cat weight! |
| 155868 |
Here you can see most of the process. Top right is one of the diff mounting nuts. In the middle are the driveshaft flange nuts, and below is the driveshaft mount and the PPF bolts. |
| 123225 |
The 14mm driveshaft nuts come off easily, just remember they are on 12mm bolts, not studs. You can see the PPF bolts here as well. |
| 152762 |
Ok, I'm NOT doing it like the factory manual says. I didn't remove the driveshaft, just pushed it forward and cabletied it to the side. I'm also NOT removing the front of the PPF. There's no need. |
| 126046 |
Unbolt the rear of the PPF. |
| 114083 |
Pry this out. It's fun. (NOT!) |
| 130905 |
Undo the driveshaft flange nuts. |
| 116200 |
You'll be able to pull the driveshaft back, but not off the diff. If you had removed the PPF like the manual, you could push the diff to the side, but I didn't! |
| 148195 |
The solution is to remove the upper wishbone bolt and let the hub rotate down and outward. |
| 143402 |
When it looks like this the halfshafts will be off the diff. |
| 152399 |
Unbolt the THREE bolts on each side. I had to use an air impact gun on the center 17mm bolt. Now you WON'T be able to drop the diff until you pry the PPF gently to the passenger side. It's actually very easy to do. |
| 162000 |
Here's the new 1.6L one, a transplant from Bob Z's car. My 1.8 rear end comes Wednesday, but I want to drive my car TODAY. |
| 156737 |
You can move the half shafts out of the way to put the new diff in. |
| 148238 |
You will need two people to put the new one in easily. Actually just set the diff on my chest and bench pressed it in while Harry pulled the PPF to the side for me. You can see the PPF holding it here, just before I bolted it in. |
| 152119 |
Put it all back together in reverse order. The only thing new is you need to jack up the hubs to rebolt the upper wishbone. |
| 155643 |
The good shot: see the pinion? see the ring gear? |
| 154414 |
Look ma, no teeth! |
| 161642 |
Man those are grunged. |
| 137330 |
The ring gear has looked better.... |
| 122591 |
Look what I found in the case! Wow! [update: I swapped this one out for a '96 1.8L open diff and then AGAIN for a low mileage '94 1.8L Torsen...yeah!] |