Jestr75

Hey guys, I just put a different borg warner diff under my XD. I pulled the cover off and everything inside looked ok, Cleaned it out and added fresh oil. It spun freely and no noise. Put it in the XD and drove out the shed and has a god awful clicking/clunking sound as though its not meshing on the teeth properly. Only makes noise going forward not reverse. Jacked the car up and turning the tailshaft by hand there is NO noise. If i turn either of the wheels by hand the clunking sound can be heard. Its an LSD and all the teeth on crown and pinion wheel looked good, wear pattern looked ok. I don't know a much about diffs so anyone got a few suggestions as to what i should be checking first??

I will strap a Go-Pro under the car and get footage as well if you like!

I think i will put the 3.89 gears in the 25 spline and get it on the road. Will see how i like it with that ratio.

Had another bit of a look at things today. The gear sets I have are the same width (must of been the beers lol) so the 3.89's will fit into my 2.92 diff. It is only 25 spline though and has a different lsd set up. Not sure how it will handle the torque but i have been running this diff with the 2.92 ratio and the T5 behind my clevo for six months with out issue. Hey Gerg, I thought i read in another thread you had a 25 spline axle diff behind your clevo? How is that holding up??

Thanks gerg. I am still deciding what i will do with it. I took an axle out my existing diff and its only a 25 spline. The 3.89 gear set looks a lot thicker than the 2.92 in there at the moment as well. Thought about swapping gear sets in it but not sure the gears will fit and i am still left with a 25 spline rear end.

Pulled the axles out and the diff centre today. Pretty ugly in the axle tubes with metal everywhere. Almost looks like it has had water in it at some stage. The axle splines were covered in it as well. Took the LSD centre apart and the spider gears looked ok to me. No bits missing or obvious signs of wear (well to my untrained eye anyway), the cones look pretty worn out and the axle gears had a bit of wear on the bottom side of them.

Already marked out a bit of my wall to bang my head against.

Thanks mate, Looks like its time to start learning about diffs . Will have to put the 2.92 back in to keep it on the road.

I was a leaf spring fairlane as I now have that diff under my XD. Didn't use the cable as it is to long for a normal sedan. Couldn't remember exactly what year it was but definitely leaf spring.

I am pretty sure I have a hand brake cable from a 1982 Fairlane in my shed. Will check its condition tomorrow. You are welcome to it if you want to pay for postage.

How is your engine coming along??

Can't upload photos for you so I will try and explain it for you. Remove the black plug and the other two smaller wires. They should just pull off. Push the metal retaining ring forward (towards the headlight glass) and twist anticlockwise. Might have to jiggle a little bit. Only turns about 10mm and then it will release from the headlight unit leaving the bulb sitting in place. The smaller bulb stays in the retainer unit. When putting back together make sure the smaller bulb is located in the hole of the headlight housing before twisting the retainer back on so you don't break the smaller bulb. Hope this helps. I haven't got anything in the engine bay to hinder me so it might be worth doing what deankdx suggested and remove the light itself.

Looked at mine today and it has a metal retainer ring that I had to push in (towards front of car) and twist. The plugs to the globes should pull off. Will try and get a pic for you tomorrow. I don't have anything in the engine bay to contend with at the moment either.

Just read your thread. It's a good read. Your heads flow very similar to my open chambers. Good work! Haven't got my engine together yet though

The starter motors for manuals have a spacer between the starter and where it bolts to the bell housing. I have used a BF falcon 6 cyl starter on the 302 Cleveland running a manual gearbox. As NZXD said you just have to grind the snout a bit to make it fit.