PhilD Posted December 16, 2002 Share Posted December 16, 2002 Hi, Having problems fitting the diff in my new car (1800 roadsport) We have the upper mounting bolt in place and located the diff centrally. One lower mounting bolt is in place but the other appears to be 2 or 3 mls out of line and so will not locate in the diff thread, any ideas are most welcome. Many thanks Phil Link to comment Share on other sites More sharing options...
scooby dooby doo Posted December 16, 2002 Share Posted December 16, 2002 the bushes need a bit of preload to get it all to line up. you a screwdriver or something in one side to lever it onto place then hammer (nylon mallet) the bolt in from the other side. fitting the diff is an awkward bu66er of a job.... Using a jack to take the weight can help. HOOPY 500 kg R706KGU Link to comment Share on other sites More sharing options...
Peter Carmichael Posted December 17, 2002 Share Posted December 17, 2002 Go back to hanging it just from the top bolt, without the washers in place. You can then slide it side to side easily and both bottom bolts can be spaced - Hanging freely like this, both bottom bolts will line up. Lastly, go for the top bolt with all the washers. Link to comment Share on other sites More sharing options...
darren f Posted December 17, 2002 Share Posted December 17, 2002 Ah, the old diff installation problem...... I think several of us have been there ☹️ The best technique I found was (similar to Peter's): top bolt in loose (make sure it has some play, my first bolt was impossibly tight), use the movement to wiggle in the bottom bolts, then you can then play around with it to get it centralised and 'washered' up. The best tip was given to me by the factory- put a good sized chamfer on hte leading edge of the top bolt (my second bolt came from Caterham with the chamfer machined out). I also hand filed a small lead-in chamfer on both bottom bolts which seemed to help. Good luck Link to comment Share on other sites More sharing options...
BruceW Posted December 17, 2002 Share Posted December 17, 2002 Might be a bit late for this but ensure the chassis threads are clean before offering up the diff by running the bolts in and out a few times with some copper slip too. I would not get the centre line adjustment sorted until you've located the lower bolts. A bit of free play around the top mountings allows you to get the lower bolts in place, this is lost if you've already got the spacers in. Once the lower bolts are in then I took out the top bolt and stuck in the washers etc. Bruce Link to comment Share on other sites More sharing options...
Colin Grundy Posted December 17, 2002 Share Posted December 17, 2002 Phil You have my sympathies. Can be a bit frustrating, but FWIW I found that putting a thinner bolt or screwdrivers through the top bolt mountings while the bottom ones are in helped a great deal. Also I found that gently filing the holes with a round file cleaned and copperslipping the bolt also helped. When everything is in place though make sure that everything is shimmed and lined up correctly. Good luck Link to comment Share on other sites More sharing options...
paulyb Posted December 17, 2002 Share Posted December 17, 2002 Phil, Agree with Colin above, use a couple of screwdrivers on the top mountings as this gives enough play to be able to wiggle things around. Get the lower bolts sorted, then the top. Reading this I realise how lucky I was....no real dramas; sorry - that doesn't help you much. Good luck. Link to comment Share on other sites More sharing options...
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