My M20 Swap

[Deutschman]

With shipping and Cali tax I think they were around $300. I know the headers fit. I plan on hacking the down pipes up a bit to make them fit.

I think I will move the o2 bung some where ells.

[Deutschman]

Just got a really nice email from Andrew over at Irrland Engineering. My hoses are on the way.

[Deutschman]

Today I ordered a Magnaflow 14815 from amazon for $159.

Just need a glass pack for the center, some 2.5" piping, and flanges.

I also ordered a M30 AFM from RobertK (on R3V).

[TKMad]

I'm curious about the fit on that Magnaflow. I was going to order one but thought it would be too tight between the tank and the wheel well. Let us know how it turns out!

[Deutschman]

Yeah I have been wondering as well. I think I will be able to get it in there though. Should sound really nice with a glass pack center, the MSDS headers, and the six cylinders!

[Deutschman]

Ma Magnaflow.

And the beginning of my fridge sticker collection.

[viali8]

When you get the e30 keep in mind that there a other parts that will fit your 2002 with no and/or miner modifications.

I have sun visors from and e30 in my 2002, and you only have to change the location of one hole. I know you can also use the front strut housings. The e30 drive shaft can also be used in the m20 swap if you are keeping the stock diff. and if the e30 you are getting has a small case lsd diff keep the lsd pumpkin because it will fit in your stock 2002 diff with a diff cover spacer.

I am sure there are probably more parts that could be moved over, but I have just not tried yet.

Are you useing the e30 struts on your 2002? If so what brake setup are you using in the front? If so what brake set-up are you using?

Thanks

Matt

[Deutschman]

I am not as of now, but might be in the future. As fare as brake set ups go you can buy big brake kits from a few places, or get brackets made and use VW carado brakes up front.

[Deutschman]

I started working on the diff project. I am having way different problems then I thought I would have. It turns out that I do not need a spacer for the diff cover at all. That part fits fine.

The problem I am having is getting the LSD pumpkin properly situated in the case in a way that the crown gear from the LSD makes contact with the gear from the input shaft in the correct way. I just cant seam to get it situated correctly.

Here is the small case e30 LSD pumpkin in the 2002 diff case.

The old 2002 open gears.

So here is a picture of the drive flange the way it is spaced out.

If I tighten this drive flange down any more the diff binds up and will not turn anymore. This leads me to believe that by doing so, I am pressing the crown gear from the LSD unit and the gear from the input shaft together way to much, which makes them bind up. I messed with the spacing on this side and this seams to be just right. Any more space and the gears do not make enough contact, and any less space and the bind and don't turn.

On the other side the drive flange is all the way in and flush with the diff housing. This is a problem because the baring from the on the LSD unit is not sitting in the out put shaft seal properly which is resulting in the LSD unit not being held in place properly and messing up the contact between the crown gear and input shaft gear.

Here are some videos.

If I put the diff up on its side, with the spaced out out put flange up, and turn the diff from the input shaft it sounds and works well.

How ever if I put the diff right side up and turn the diff from the input shaft it makes all kinds of bad noises.

I just cant get the LSD unit to sit in the case snugly enough so that it does not move in unwanted directions, and in a way that the two gears contact each other in the right way.

I feel like I am just going to have to keep messing with the spacing of the drive flanges to get the LSD unit situated correctly.

If anyone has any history with building diffs please chime in!

Cheers!

[Fishhead]

I havent rebuilt any diffs, but I think I would use the ring gear from the 2002. The ring gear teeth look shallower(from where it mounts to the "pumpkin") than the other ring gear and they are a matched set.

Heres a link to Quaife diffs. If you click on the 2002 diff, it says that other parts are needed to put the LSD in a 2002 case.

http://www.quaife.co.uk/shop/search/results/qdf4n

See pic.

I dont think that you should have the "space" that is shown here. Maybe the 2002 ring gear is thinner and will eliminate this space ans allow the pumpkin assembly as a whole to be pushed over to eliminate this space.

[Deutschman]

Very good thoughts!!!

Thanks!

[Deutschman]

I havent rebuilt any diffs, but I think I would use the ring gear from the 2002. The ring gear teeth look shallower(from where it mounts to the "pumpkin") than the other ring gear and they are a matched set.

Yes! Thanks for helping! I ow you a penny for your thoughts! ; )

It works really well now. I just switched the ring gear (crown gear) from the 2002 diff onto the e30 LSD pumkin. Now there is a mached set of 3.64:1 ring and pinion gear in the diff. All I need is a new baring (we had to bust one today), and some new seals. I am super stoked!

[Fishhead]

Glad I could help..

Could you make a list of what parts you used (stub axles, bearing retainers,etc/ 2002 or E30) to make it easier on those (ie: me) who are contemplating the same swap in the future.

[Deutschman]

I plan on doing a full write up with pictures and parts list. Ones I get the new seals and bearings I am going to take the thing apart again, clean it, and take pictures while reassembling it. Then I can do a DIY write up.

[Tommy]

Did you swap also the pinion shaft with the ring gear when you got it fit? Or did you first try with pinion from 2002 and ring from e30?

I have also tried putting e30 lsd stuff in 2002 case and I'm in same situation. The lsd unit is off by about 6mm. I really haven't had the time to put in this.

Tommy