Order of build - R400

[Charlie XGO]

Hi...I am building a new R400 kit. Owing to some shortages, I can not install the engine/gearbox combo at this point...so I have begun to consider the installation of the Differential! Questions:

1) Is it okay to install the diff before the engine?

2) Would you attach and torque (with Locktite?) the Propshaft bolts to the Diff BEFORE you install the Diff ...book says after, but there is not much room to work once the Diff is in.

3) Therefore, once ready to install engine/gearbox, spline of installed Propshaft can be inserted into the back of the gearbox? easily?

4) Any ideas/tips on how to best get the diff in place...I am strong, but it is a lot to hold on chest while working the bolts!!

5) Best guess on number of Thin and Very Thin washers to put on each side of diff at lower mounting point to get the Diff tight and squared up with in chasiss. I am sure it is not a perfect science, but an estimate would hlep!

 

Thanks very much for help and suggestions!!

[Peter Carmichael]

Boit prop to diff out of the car.

 

With the boot floor out I have used a sling to support the weight of the diff, although my fave method is to have the diff on a black and decker workmate and have the back end of the car slung fro an engine crane and gently lowered. Don't try and get the bolt through at first attempt use a large screwdriver to catch the diff and then when inserting the bolt push the screwdriver out from the other side.

 

The washers *need* to be particular to the car. They make up for production tolerances. In practice it is easy to measure these. Just get the bolt all the way through with no washers and the diff can slide from side to side to be measured and the washers checked for thickness by edging them into the gap.

[mav]

Hi Charlie. Nice build to have - should be a stormer once completed.

 

1. I would hope so!

 

2. I'm sorting that in the car.

 

3. Should slip in nicely.

 

4. Use a jack / wooden plate to sit it on.

 

5.Measure and measure again. Each is different.

 

Reagrds

 

Martin

[Roadsport06]

 

I put grease on the washers as it holds them together, you might need about 4 for each side, but the diff needs to be central so as Peter says they are "particular" to each car.

I put the diff on my chest and chest pressed it up, it was a little silly when you hold it with one hand and put the top bolt through with the other. I think a bottle jack has been used by others to help though but better if you can get a friend around to help on this one.

Do as Peter says with putting the diff in without the washers and then put them up to work out the right number.

I torqued my diff to prop bolts up with engine and gearbox in and the car in gear and brakes on.

 

BRG and Yellow nose VU06 XZX

 

[Charlie XGO]

Peter, Martin and James,

 

Thank you for your rapid responses. I sent my question and then went away! I will get cracking on the installing the Diff tomorrow, Propshaft attached first (final torgue later when shaft imobilied by engine), using a jack to lift into position...sounds as if I am in the trial and error catagory for number of washers required to center the Diff!

 

General question, if you recieve this note: When to Copper Grease and when to Locktite? Seems that there is need to Copper Grease nearly all fittings and bolts, except a limited number where the Guide specifies Locktite (which is not very often)....Where would you use Locktite in your optinion? Gear box to bell housing, Propshaft to Diff, etc?

[Roadsport06]

Only used loctite when said in manual.

De dion ears, prop to diff and I think the bottom of front suspension mounts, there may well be more, but most are as you say copper greased and torqued up.

 

If you post on here you will usually get a reply in a few minutes (thats if its a slow day!). blatchat was very useful for me on my build

 

BRG and Yellow nose VU06 XZX

 

[Charlie XGO]

Thanks James...you can be sure I will be using Blatchat a fair amount over the coming weeks (unfortunately it will be a weekend build and with holidays, not every weekend forthcoming).

 

I note your car is BRG and Yellow nose...my number one preferred colour scheme! However, wife has a phobia against green cars as she rolled one, so no green in the auto catagory, so I pained my racing bike (cycle) BRG!

 

regards,

[rj]

I have chamfered the bolts for the diff which has made it quite an easy job to install it.

 

No boot floor helps too. But as Peter says fit propshaft to diff before offering it to the car. Or at least remember to leave the propshaft in the tunnel before fitting the diff - otherwise you'll soon learn how to remove a diff 😳

 

Welcome to the madhouse by the way

 

/regin