cantdrv65

iTrader: (3)

Alright I just sent some more debris through the rear cover of te 10 bolt. After pulling the cover , I see a Sheared off bolt. The bolt is one of the four that hold the Torsen differential assembly together. they are located on the same side as the ring gear bolts but more towards the center of the differential unit. This is the second time i have sheared one of these bolts off, the latest being a grade 8 bolt. It did not cause any damage to the rest of the rear, gears and bearings look fine, it just shot it through the cover. What the hell is causing this?

Rob SS

I'm curious too! I have the exact same problem. I just pulled the cover to find a bolt head sheared off on the carrier.

cantdrv65

iTrader: (3)

TTT.....P.S. The car makes 500+ rwhp...Rob are you spraying your car?

Rob SS

cantdrv65 - I'm putting down only 360 rwhp & rwtq. This is on A4 stock converter.

cantdrv65

iTrader: (3)

<img border="0" alt="[bang head]" title="" src="graemlins/gr_banghead.gif" /> Wierd. Anyone?

cantdrv65

iTrader: (3)

I just called the engineers at Torsen and this stomped them as well. <img border="0" title="" alt="[Confused]" src="images/icons/confused.gif" /> I'm just going to replace again with grade 8 bolts 1/2"/13 and torque and locktite per thier recommendation of 110/ft lbs. They were very interested in this, and want to know if anyone else has seen this problem. They are also familiar with ls1tech.com. <img border="0" title="" alt="[Smile]" src="gr_stretch.gif" /> It's Moser time. <img border="0" title="" alt="[Wink]" src="gr_images/icons/wink.gif" />

Rob SS

cantdrv65 - what the lenght on those bolts 1/2" 13...x 2"???? TIA.

cantdrv65

iTrader: (3)

I used 1/2" 13 * 1 1/2" .....Make sure to locktite and torque to 110 ft lbs. I also used Grade 9 bolts, which were basically an improved grade 8. If the same problem happens again I'll have the cap welded on and the bolts welded in. <img border="0" title="" alt="[Wink]" src="gr_images/icons/wink.gif" /> It's Moser time soon anyway. <img border="0" title="" alt="[Smile]" src="gr_stretch.gif" />

Rob SS

I finally tored down the diff and found the right bearing pitted badly. Also disassembled the torsen and found hairline crack on the cap end where it was snapping the bolt heads.

Extinct SS

This just happened to mine, how did you get the broken bolt out?

Rob SS

Wow! This was long time ago.....I ended up pulling the carrier from rear end, drilling and use a screw extractor (EZ out) but you might want to find out why you are shearing those bolt heads. I ended up shearing more bolt heads later on after the fixes, found out the carrier was bad. Check out the carrier for any unusual wear and stress cracks. Good Luck.