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Quieting down the Zexel

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Old Aug 10, 2005 | 01:13 AM
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Default Quieting down the Zexel

So I just had my ring and pinion gears swapped as well as replace all the bearings on the rear, used the RAtech master install kit... even axle bearings included. Everything is great so far. Mechanic just looked at the car over the weekend (after 2 weeks of drivng on new gears) and checked the wear pattern, pinion, and everything checked out great. No metal shavings or anything to indicate any problems.... So there is nothing wrong with the rear.

I have noticed though what is described as "rocks in a box" sound on deceleration at low speeds, and have researched it a bit and found that the culprit is usually the Zexel-Torsen unit.

So here is my question, what can I do to quiet it down? I already have a bottle of GM additive in there. I used castroil synthetic rear end gear oil... Im thinking of trying Lucas, and adding 2 bottles of GM additive instead.

What do you Zexel guys use?
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Old Aug 10, 2005 | 12:16 PM
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You didn't change the differential? Then the noise isn't the differential. It wasn't there before, but is now with the same unit in place.....

Most likely a bearing problem. The growl when they are bad or are dinged up.
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Old Aug 10, 2005 | 03:55 PM
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Originally Posted by Sam Strano
You didn't change the differential? Then the noise isn't the differential. It wasn't there before, but is now with the same unit in place.....

Most likely a bearing problem. The growl when they are bad or are dinged up.
All bearings were replaced. I had one axle bearing that was beginning to pit, but it was replaced. Everything in the rear is good except for the sound. After 40k miles when the cover was taken off, nothing out of the ordinary, no chunks of metal or anything. When the rear was just inspected after about 300-500 miles....no metal shavings, no big pieces of metal, bearings all looking good.

Like I said the noise is in line with the description of the loud Zexel. Only at low speeds and on a turn. It sounds like a box of rocks, and is not a growl. I have dealt with that before.

I think I am just going to try and use Lucas gear lube and add an extra bottle of GM posi additive like the TSB says.... hopefully I wont have to hear it then. If not I guess I can always go with an Auburn
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Old Aug 10, 2005 | 04:06 PM
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Ok, whatever you say. My point was simply that is seems you had no noise before with the same differential, and you do now, but the unit is the same as it was.......

Torsen's don't need or use additive because they have no clutches in them. And just because you have new parts doesn't mean one can't be bad out of the box.

Try the fluid, but it doesn't add up.
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Old Aug 10, 2005 | 04:56 PM
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my 2 cents. some will mention the noise is from the zexel-torsion is normal. from my experience, there should be NO noise. my rear-end has been rebuilt by the dealer 3 times, this 3rd time i think they finally go it right. i've had the "marbles in box" noise before and it wasn't there when i first purchased the car, and it's not there now.

fwiw, my car is over 5 years old AND is daily driven. i'm very tuned into the noises. i don't believe anyone should hear the "marbles in box" noise from a good stock rear.

anyway, if the additive quiets it down, then that's great. but like sam said, it's not necessary with the torsen.
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