320i LSD conversion question. Half of you probably know this

[BMtroubleyou]

Alright, I saved myself around $80 - $100 that aardvarc racing was charging for the LSD conversion kit for 2002's. I found a fabricator and hardware store to give me spacers, bolts, and to drill and tap the new 8mm on my flanges.

Last thing left is the install. The diff was bone dry inside because of shipping regulations when I purchased it out of state.

How do I know what level to fill up the LSD at after taking off the 320i diff cover and swapping on the 2002 diff cover that doesn't have a fill hole? There's another fill hole on the diff housing itself right on the top corner next to the driver's side axle flange, however it's about an inch higher than the fill hole on the 320i diff cover, meaning that there would be a considerable amount of more fluid going in, possibly damaging everything inside when everything's moving. What should I do, and what type of fluid should I use? I remember doing a service on my Z3 LSD and had to put in a graphite additive. Would I need to do that this time to?

Would appreciate any feedback on this, and I may start mass producing the conversion kits and selling them for half of what other bmw performance companies are charging so i'll keep everyone posted if they'd like to save some bucks.

(O=00=O)

[Guest Anonymous]

How do I know what level to fill up the LSD at after taking off the 320i diff cover and swapping on the 2002 diff cover that doesn't have a fill hole? There's another fill hole on the diff housing itself right on the top corner next to the driver's side axle flange, however it's about an inch higher than the fill hole on the 320i diff cover, meaning that there would be a considerable amount of more fluid going in, possibly damaging everything inside when everything's moving. What should I do, and what type of fluid should I use? I remember doing a service on my Z3 LSD and had to put in a graphite additive. Would I need to do that this time to?

(O=00=O)

Maybe more than 1/2 of us know this.

I do not recall any fill hole on the differential cover. There is a vent hole with hardly any suggestion that it be used for anything other than a vent. If you are using the 02 cover plate, there is no fill hole (unless someone machined one there) SO the point is nonsensical.

Use the hole that is on the housing as the manuals for both models indicates.

hth

[jimk]

Those of us that don't know, think it thru.

Simple, the fill plug is located on the housing you installed for THAT housing. It's in the right place.

[PatAllen]

i toped off mine using the 02 cover fill hole. been fine like that since year 2000 with 250+hp.

[Retrogroucher]

Yep, fill it 'til it leaks out fill hole w/ car level. An overfill condition creates rust inhibitor on the underside of the car and exhaust-- not advantageous.

[john_a]

If you are using the 02 cover plate, there is no fill hole (unless someone machined one there) SO the point is nonsensical.

Use the hole that is on the housing as the manuals for both models indicates.

hth

Actually, BMW Service manuals for both the 2002 and the E21 show the fill plugs on the diff covers. What manual are you referencing?

All the 02 diff covers I save are the late finned ones, all have the fill plug on the left side of the COVER. These covers all came off 02 diff housings that had no fill plugs on the cast iron housing itself.

All the E21 diff housings I save are the late six-bolt cap (as opposed to the earlier four-bolt bearing cap types) and none of these have a fill plug on the cast iron housing. They do have a drain plug on the right side of the housing, but I doubt anyone could confuse that for a fill plug.

Pic of E21 cover with fill plug at lower right:

Pic of 02 diff cover with fill plug just visible on left side:

[BMtroubleyou]

great, so it's confirmed that the filler plug area is on the housing on the drivers side, on the top right corner. Now what type of gear oil should I use? Does it need to be synthetic? Do I need to put in any additives?

[Guest Anonymous]

Whoa! I am wrong. I admit it. No defense.

I am currently nursing a twisted ankle that I got from tripping over a side loader differential from an E24. It is being used as a door stop right in front of me. I know the difference. I misread the post regarding two fill holes (as opposed to drain holes). I jumped to a bad conclusion that we were referring to the side loader.

I will go back to lurking now!

My sincere apologies.

[john_a]

great, so it's confirmed that the filler plug area is on the housing on the drivers side, on the top right corner.

Almost!

Except for the fact that the fill plug is not on the housing, and not anywhere near the top right... I hope you're kidding now, esp. after saying that your cover had no fill plug in the first post. It sounds like you are still planning on ripping out the vent and overfilling the whole thing up to the top?

[TobyB]

Put a quart in and drive it.

There is a fill plug on the rear cover.

Use Redline 90-140 gear oil.

Don't drop it on your head when installing.

t

[BMtroubleyou]

Put a quart in and drive it.

There is a fill plug on the rear cover.

Use Redline 90-140 gear oil.

Don't drop it on your head when installing.

t

where is this fill plug on the factory 02' rear cover?? i'm not finding it.

[BMtroubleyou]

great, so it's confirmed that the filler plug area is on the housing on the drivers side, on the top right corner.

Almost!

Except for the fact that the fill plug is not on the housing, and not anywhere near the top right... I hope you're kidding now, esp. after saying that your cover had no fill plug in the first post. It sounds like you are still planning on ripping out the vent and overfilling the whole thing up to the top?

ok, we are both at fault here. You obviously haven't read above that I can't keep the 320i cover with the vent because it will not mount up to an 02' which is why I have to swap the original open end diff cover to the 320i LSD in order for it to mount up. I could care less about that 320i cover...

I just discovered that when I bought the 320i LSD someone had taken off the cover and reinstalled it upside down. since I innocently enough have never seen a 320i diff before I couldn't tell the difference until now. (This is why I ask questions if things don't seem right)

so why don't you be helpful and simply tell me where the fill hole is with the original 02' cover, or anywhere it's located for that matter. You seem to know everything right?

[john_a]

[

ok, we are both at fault here. You obviously haven't read above that I can't keep the 320i cover with the vent because it will not mount up to an 02' which is why I have to swap the original open end diff cover to the 320i LSD in order for it to mount up. I could care less about that 320i cover...

so why don't you be helpful and simply tell me where the fill hole is with the original 02' cover, or anywhere it's located for that matter. You seem to know everything right?

Dude, chill out.. you need a thicker skin if that bothered you. If I was being a bit sarcastic, it's just because it was hard to imagine after describing where it is on a 2002 diff cover (yes, I read your post well enough to understand what you were doing) AND posting a picture showing where it was on a 2002 diff cover, you still wanted to look for it on the top right of the housing? It was pretty ironic that you'd assume that after being shown/told it was not on the housing, not on the top, and not on the right. I really was not sure if you were serious or not. Twice in my first post above, I make a direct reference to the location of the fill plug on an 02 diff cover, still not sure how you missed that and assumed everything was about the E21 part when I wrote "All the 02 diff covers I save are the late finned ones, all have the fill plug on the left side of the COVER."

Sorry if you are offended, but it you want people to help you, it helps to at least show some sign that you are paying attention to the advice given, or it's just a waste of time to post answers.

Please prove me wrong, and show that you can make use of the help provided for your benefit.

Your picture of the right side of the 2002 diff cover misses it cuz' it's on the LEFT side.

Please re-read the post I made earlier, pay attention to the part that says:

Pic of 02 diff cover with fill plug just visible on left side:

Now look along the left side of the cover. The fill plug is just below the middle bolt on the left side. It is not the clearest view, but it is enough to show where it is with the text pointing you where to look.

Maybe you don't have a fill plug (but I doubt that very much) but do trust me that I was (and still am) trying to help you find it as best as I can.

[TobyB]

where is this fill plug on the factory 02' rear cover?? i'm not finding it.

...on the other side... driver's left...

t