OBX LSD rebuild step by step pics inside

[Erik W. Treves]

Got my OBX LSD tonight and jumped right in. Thanks to Wayne Presley for mentioning something about a "washer upgrade" kit for these things...he just saved my brand new/rebuild tranny....thanks brother!!!

ok so here are the first of several installments of North Alambama East Coast Speed Machine 818 Build

new and old side by side....not sure why the ends are slightly different...the LSD is for a 2002-2005 WRX...

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08181606.jpg

mark everything since it was my first time, really wasn't required because it can only go back one way..see later

I put the drifts in there to keep the LSD from rotating while I removed the bolts.

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08182416.jpg

Remove bolts and split the LSD....you will need to pry it apart..go slow it will be hard and then it won't be

here it is with the cover off..
http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08183209-1.jpg


Pull the shaft end out, just rotate it with the grain and it will slide right out...I numbered everything just in case the "erik factor" showed up and the little planet gears went all over the place...

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08183429.jpg



here is the cover flipped over on the bench

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08183219.jpg


Next pull out the center top middle gear...the black washers that we are after are under the gear.

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08183457.jpg

[Erik W. Treves]

these are the washers we're after

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08183528.jpg

I put my pointer finger in the hole using it as a "washer removal tool"...the idea being I did not want to lose the order in case it the directions were wrong...they we're correct and there were 6 washers. )()()(

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08184142.jpg

old washers stacked next to the top gear

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08183634.jpg

old washers next to new washers

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08184040.jpg

the inside of the diff...the instructions said something about taking the other gear out...not sure why...

Going back together...reverse the process ... sticking my finger in the washers I was able to put them all at once.

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08184220.jpg

then put the top gear back on

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08184249.jpg

it does stick up a little..this is normal

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08184303.jpg

[Erik W. Treves]

Install shaft

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08184410-1.jpg

install cover..here you can see the index stud...It can go on any way but it will only torque correctly with the index pin in the hole..

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08184436.jpg

[riptide motorsport]

Thanks....I'm going to save this thread.

[Erik W. Treves]

Install the bolts and torque them down...GO SLOW and make sure you compress the washers straight and even and the cover doesn't tilt...more to follow...

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08184509-1.jpg

[Erik W. Treves]

so what "I" did was bring the bolts down on the cover (took a while) and then torqued them per the directions....THEN...backed one at a time back out, BLUE lock tight, then put it back in, a final torqued and marked so the "Erik Factor" couldn't "help" me do the same bolt twice... and here it is done...washer upgrade complete!!

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08203517-1.jpg

[Erik W. Treves]

so what's the big deal about making sure you go down straight?? well the moron that put it together at OBX didn't....this is what the bolts looked like when I pulled them out.. the threads were mashed... which made putting the new bolts back in extra fun (Which is probably why they come with the kit!)

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-08203001.jpg

So what's the big deal about the washers??

Here is one out of the never installed LSD....it is already starting to come apart!! the washers actually bite into one another and dig ridges...this one dug all the way to the edge (12 o'clock) and started to split off...

http://i42.photobucket.com/albums/e344/TREVESK/818/IMG_6183.jpg

THANKS WAYNE for recommending the washer kit!

tomorrow..I move the ring gear over to LSD and install in the tranny.

[Erik W. Treves]

Thanks....I'm going to save this thread.

that's why I posted it ;)

[GUNS]

So that's it for the OBX LSD re-build? Doesn't seem as bad as I would have imagined. Thanks for the write up!

[RM1SepEx]

Plenty of similar write ups on the Subaru forums... several also indicated incorrect machining to check as well as bolt and belleville washer replacement. The OBX is a cheaper copy of the Quaife. That's why I bought the Quaife instead... At 2x the $... :-(
nice job documenting the rebuild Erik!

[Erik W. Treves]

yeah, for sure I don't think I would the OBX out of the box...but since the kit it still months away...I have plenty of time :D Seems like after the rebuild the Subaru crowd doesn't have an issue with the diff and all reports are very good...we'll see

[freds]

yeah, for sure I don't think I would the OBX out of the box...but since the kit it still months away...I have plenty of time :D Seems like after the rebuild the Subaru crowd doesn't have an issue with the diff and all reports are very good...we'll see
Hi Erik, my sentiments exactly. I have also bought an OBX and opened it up to clean up the burrs and rough edges etc. I'll be starting on my transmission in the next few weeks, and be interested, since you are ahead of me on this, where you are sourcing the new carrier bearing and seals for the diff. Also I'm sure I'll be asking about details when resetting the diff in the transmission (if you don't mind)
fred

[longislandwrx]

great pics, thank you for taking your time to do this.

I know the link had been posted before but can you include it since this is sure to become a popular thread?

[Erik W. Treves]

Done!

http://i42.photobucket.com/albums/e344/TREVESK/818/2013-01-09181550.jpg

[metalmaker12]

Nice documentation, It should hold up, I put one together with the better washers in a 04 wrx and it held up with a year of abuse until I sold the car.

[C.Plavan]

Not to be a Debbie Downer, but I want to put this out there in this thread for other builders. No disrespect to the above posters, but it is a known fact that these cheap copies and are not that great. OBX is an "Ebay" quality disposable TBD (1.5way diff). You will be rebuilding them a lot.
Personally, I would stick with a Quaife unit for a TBD, much better quality. But for my 818R, a 2way LSD is a must. 2 way LSD's are for race cars.

[flynntuna]

Great write up! With write ups like this one even I should be able to build this project.

[StatGSR]

Not to be a Debbie Downer, but I want to put this out there in this thread for other builders. No disrespect to the above posters, but it is a known fact that these cheap copies and are not that great. OBX is an "Ebay" quality disposable TBD (1.5way diff). You will be rebuilding them a lot.
Personally, I would stick with a Quaife unit for a TBD, much better quality. But for my 818R, a 2way LSD is a must. 2 way LSD's are for race cars.

While i don't entirely disagree, the track record of rebuilt OBX units is pretty solid from everything i have seen. Its the carelessness on the assembly of them in the factory that is the biggest problem, not the pieces them selves. That is the reason why this thread exists!

[apexanimal]

And do check the oiling ports and whatnot as well... With a little DIY spirit these do hold up...

[RM1SepEx]

most sube feedback on the OBX has been good after the rebuild... I have seen a couple threads however where the machining was poor and you could visually see that it wasn't machined properly.
I understand that they hold up justn fine usually.

I went with the Quaife as I didn't want to deal with it and I was making a big investment in the 818. The Quaife is a very well made piece and bulletproof in my street and autocross use application.

No self respecting 818 should go w/o a LSD ;):rolleyes::)

[longislandwrx]

No self respecting 818 should go w/o a LSD ;):rolleyes::)

+1 this. no peglegging.


ALSO. just received preorder update 3. very exciting stuff.

[Silvertop]

..............

I went with the Quaife as I didn't want to deal with it and I was making a big investment in the 818. The Quaife is a very well made piece and bulletproof in my street and autocross use application.

No self respecting 818 should go w/o a LSD ;):rolleyes::)

This thread has caused me to seriously consider including an LSD in my build, even though it is going to be pretty much a pure streeter. A question: All the vendor sites I visited seem to offer the Quaife unit for 1993 to 2000 model 5 speed transmissions, and 2001+ for 6 speed transmissions only. What did you use?

Also, what level of transmission disassembly will be required to install the LSD?

[Erik W. Treves]

you have to take the tranny completely apart...remove the back half, split the case, remove the gear set and then pull the front diff out. this is what mine looks like right before I put the diff back in...not too hard really...but it is a process.

http://thefactoryfiveforum.com/attachment.php?attachmentid=14467&d=1358350870

[longislandwrx]

you have to take the tranny completely apart...remove the back half, split the case, remove the gear set and then pull the front diff out. this is what mine looks like right before I put the diff back in...not too hard really...but it is a process.

and you'll get a real good look at everything in there. If you bought a wrecked donor you may have mulched gears you don't know about.

Erik, do you have a good how to you are working off of?

[Silvertop]

you have to take the tranny completely apart...remove the back half, split the case, remove the gear set and then pull the front diff out. this is what mine looks like right before I put the diff back in...not too hard really...but it is a process.

http://thefactoryfiveforum.com/attachment.php?attachmentid=14467&d=1358350870


Posted by Longislandwrx

and you'll get a real good look at everything in there. If you bought a wrecked donor you may have mulched gears you don't know about.

Erik, do you have a good how to you are working off of?


Thanks for that input, guys. I've built an engine or two in my time, but I've never been inside a transmission. A little scary. Still, wonders may be achieved with the help of a suitable workshop manual. Haynes Manual good enough? I suppose I have the option of having AJW do the install for me, before they ship my donor pallet to me. Though if I'm going to do that, I better act fast. The AJW donors have started to ship........

Not too worried about mulched gears. This particular car (an '04 NA Outback Sport) was actually being used by Andrew Wallace as a daily driver before he made the decision to sacrifice it to the donor program. Says it was a nice car, a nice driver, and a tough decision.

Still looking for input on the LSD year classes available from Quaife for my '04 5-speed.

-- TX

[wallace18]

You can get a factory manual on a CD from Ebay for about 10 bucks. It has everything you need to do anything on the WRX.

[longislandwrx]

I have that, a good reference for specs and steps, but I prefer how tos by normal guys in addition to add the real world experience element.

[Erik W. Treves]

same manuals that you can get access to...only difference, I have also made REALLY GOOD FRIENDS with the Subaru maintenance techs....additionally... Wayne Presley has a wealth of experience rebuilding similar transmissions... I pretty much use him exclusively for any Factory Five related items though he works on any FUN CARS... you can bet when I get to tuning my F-150 EcoBoost it will be down in his shop! It maybe far away, and cost money out of my pocket, but, it's a one and done deal every time.

[RM1SepEx]

My Quaife install is ongoing, a side project for a sube expert/friend at a shop. He found my carrier bearings were bad.... very slight"doesn't feel quite right" They are now on order... over $100 for each...WRX only had 70,000 one ownewr miles, no engine mods.. 3except intake. Yet the transaxle wasn't quite right. Who knows it might have had to problems with those bearings for 100,000 more miles.

The online manuals specify several special tools... I didn't want to deal with it and subbed it out.

Great thread Erik

[Erik W. Treves]

ya think this one is good...got the call from Coparts and Wayne this morning....my donor will be here FRIDAY!!!! Now we'll get down to business!!!

[tmoretta]

Still don't get what the "washer kit" accomplishes, and where you get it. Does it come with the LSD? What if you just install the OBX in the front trans. as is? Isn't it made for that appication?

[longislandwrx]

The washer kit is an upgrade for the garbage bolts/Belleville washers that come installed in the OBX differential. Look at the picture in post #7, the washers are often already damaged like this from the factory. they crack, splinter, distort and generally don't last long. The bolts are cheap quality as well and are sometimes cross-threaded from the factory. Failure of either of these at best causes metal in your transmission and a noisy differential, and at worst converts your expensive transmission into an anchor.

http://rbryant.freeshell.org/obx_washers.htm is the source of the upgrade kits and talks more about component failure


What if you just install the OBX in the front trans. as is? Isn't it made for that appication?

you might be ok, you might not be. for $35 it is a no brainer and worth the 15 minutes it takes.

[tmoretta]

Anybody know anything about the Toioka brand helical type limited slip available for about $850?

[Xusia]

I think it was in another post, but the gist of the feedback was that people have used nearly every brand & model, the Quaife is among the better, and the risk the off-brand ones pose isn't worth the savings of $150 over the Quaife. If you want to save money, the OBX listed in this this thread is good so long as you replace the washers.