Front Diff or just inner CV joints? URGENT

SVX ROO · #1 10-10-2005, 05:07 PM

My wife's '94 developed a severe clicking that turned to clunking. I got it home doing last 5 miles at 20 mph. No issue with engine. Tranny was shifting smooth thru all 4 gears (while I could still get it up to 40+ mph). It sounded like the right front inner CV joint had completely broken its cage and lost a ball or two. (OOCH!)

I now have it jacked up and I was at least close to the issue. The inner CV joints (both) have some play in rotation mode, but not likely enough for the racket it was making. However, both CV joints move angularly relative to the differential. This seems quite strange. Can the outboard bearings on the diff go so bad as to creat this type of problem? Or could there be more severe problem with the diff itself? It is like the extended shaft inside the diff is floating in space. Any ideas? Surely, I am not the first with this issue!

It appears access to the outboard diff bearings is quite reasonable. After pulling the shafts out, there is a large bearing holder that requires a special tool or some gentle tapping of the fins on the holder. Has anyone ever changed these bearings that way? What adjustment is required when installing the new ones? I am not yet sure they are the problem, but if easy to do it would not hurt.

Any idea what the labor would be for a dealer to R&R (remove and reinstall) the diff and do a rebuild? My dealer is Miller in Mt. Holly, NJ and he is quite reasonable versus some Subaru dealers.

First priority is help with the diagnosis. (Car has about 175K miles, 20K less than my '92)

Ken

Manarius · #2 10-10-2005, 05:47 PM

I'm going with CV joints. Front diffs only break when you have Tom dropping neutral drops on them all the time.

TomsSVX · #3 10-11-2005, 08:03 PM

are the boots for the cv's torn?? It could be that the diff is toasted, drain the diff fluid(finned pan) and look for any tiny or large chunks of metal... Changing differential bearing can be more than carrier bearings, it can be pinon bearings too. Not to mention, when diff bearings go bad, they wear down on the gears and eventually get to a point where you can shave with them....hence why they break... My first SVX had the diff expode. The seals for the axles went bad and drained the fluid out. Bearings went bad and well the gears got chewed from it. Let me know if you need some help, I got some extra parts around here somewhere....

Tom

LarryIII · #4 10-12-2005, 08:10 AM

Ken,

Thanks for the e-mail on this. I've never experienced any diffy problems with SVXes, so I can't help. Do drain the fluid and inspect it. There have been cases of ATF leaking into the front diffy causing problems.

SVX ROO · #5 10-12-2005, 08:48 AM

Tom et al

CV boots are NOT torn, I was hoping they would be. Inner CV's seem to have play but I do believe it is the diff.

I spoke to service at Miller Subaru and he said it sounded like the spyder bearings. Apparently, diff problems with the SVX are pretty rare.

I plan to do exactly what you and Larry suggest. I'll drain the diff into a clean pan and see what 'goodies' I find. I will pull the right side half shaft and see what I find as well as seeing if it needs rebuilding as well. It is likely to be Sat. before I get to it (see below).

If the diff needs work I will send the car to Miller and let them do it; it is too big a job for me. However, they were open to using a used diff from someones bad tranny. Tom, send me a separate email and let me know what parts you have that are good. Send to <lotuselan2@comcast.net>, include your phone number.

To make matters worse my '92 Pearl decided to snap its throttle cable on the eastbound ramp of the Betsy Ross Bridge yesterday afternoon. I'm chasing the new cable and hope to have it back on the road this weekend. Now my wife and I are sharing an '88 Escort Wagon! (The Lotus is apart now too.)

TomsSVX · #6 10-12-2005, 12:50 PM

I will send ya an email... I dunno how much I would trust a guy calling something a spyder bearing though.... There is no such part in a diff, There are pinion bearings, carrier bearings spider gears, ring a nd pino gears etc but no spider bearings.... Check this guy out..

Tom

SVX ROO · #7 10-12-2005, 04:52 PM

It was me that used that term. I think service rep correctly called them spider gear bearings.

TomsSVX · #8 10-12-2005, 05:03 PM

still, the spider gears don't have bearings

Tom

SVX ROO · #9 10-17-2005, 05:56 PM

Here's the update:
+Drained diff and no metal seen, a trace of grey paste only
+Check RH CV joint, a bit worn but not the problem
+Took to dealer - he says diff is broken and he will not rebuild the diff on a tranny with 175K miles.
+I just bought a complete '96 tranny on ebay.

Will a '96 tranny fit a '94 (both AWD)?? Any mods needed?

TomsSVX · #10 10-17-2005, 06:07 PM

as long as it is a 96 tranny for an SVX. Gear ratios matter

Tom

SVX ROO · #11 10-18-2005, 06:30 AM

Tom
What do you mean "gear ratios matter"? Is the diff ratio the same? If the internal gears have different ratios I might see some performance change but everything will work okay.

Is there any issue with the casings or trans. mount being different between 94 and 96?
Ken

TomsSVX · #12 10-18-2005, 10:01 AM

there is no difference in mounting... The reason I say ratios matter is if it is not an SVX trans it could have 4.11 or 4.44 gears which means you would have to swap out the rear diff as well, unless you like the idea of roasting your variable center diff clutches

Tom

SVX ROO · #13 10-18-2005, 02:03 PM

Tom
Yes, the tranny is an SVX not Legacy or other Subaru. The Service Department thinks (oxymoron) that there may be a difference in the wiring harness. He first said in the harness and plumbing but the techs said that that plumbing was okay. Do you know of any difference in the harness. If so is that easily solvable? Dealers are not much on customzing things like wiring so I might end up with the job back on me. (or on my back!)

Dealer was definitely in favor of using a '96 trans versus a '93 that I might be able to get. If the '93 is still the original it would be problematic.

I think we are getting close to getting this done! Thanks for your continued help.
Ken

TomsSVX · #14 10-18-2005, 02:16 PM

the 96 tranny does have revisions that the 93 wouldn't have in flow pathways inside the trans to increase cooling. The wiring should be plus and play with no issues at all... If they say no, I can come to where u r and give you a helping hand, I can be quite handy with trans removal/installation

TOm

SVX ROO · #15 10-19-2005, 06:51 AM

Tom
Thanks so much for your help. I have used this dealer for more than 10 years starting with an Olds Cutlass that made it to 280K miles and was still running when sold. They are working with me on it. I am hoping just to write them a check and be done with it. If I end up with car back home I will be in touch. I understand you are in LBI or near there; that is about 1 hour from me. My garage is heated and air conditioned and good sound system. Send me your phone number off line to <lotuselan2@comcast.net>. Thanks again.
Ken