Ok so its taken me 3 nights trying to get the diff in place using poly mounts.

 

What is the correct way in fitting the diff? I've been locating the rear threads in to the 2 cups first then trying to bolt the 4 bolts and bracket to the front of the diff. But when I try to align the bolt holes up they are about 5mm out.

 

What am I doing wrong? Pic below

 

Thanks Dan.

Not done the diff yet but it sounds like every job i ever do on the car...it all sounds straight forward then something like this happens and drives you up the wall.

 

i don't know if this is any different to how you are doing it but I found a guide online which says:

 

Differential Re-Installation:

Roll the differential back under the car and lift it using your jack. Lift the front of the differential, the driveshaft flange, over the anti-sway bar and push the whole differential forward. This should give you enough room to rotate the back end up and align the studs on the differential with the holes in the rear bushings(Don't put the little cups back in yet....) Move the differential as far back into the rear bushings as you can now. Move the differential by lifting it on the floor jack and moving it side to side by hand until you get the studs pretty much centered in the bushings. Tap the metal cups over the studs. The inside of the cup should face you(face the rear of the car) as you are tapping it on. Once it is on far enough, start the nuts on each stud. Leaving things loose, turn your attention to the front of the differential. I had to remove the floor jack to get enough room to slide the front differential support into place, but you may not have to. Move the

differential slightly as needed to get the 4 bolts started, no alignment problems at all here! Loosely tighten all 4 bolts and 2 nuts holding differential into place.

Find your alignment marks on your half shaft flanges and driveshaft flanges, and reinstall driveshaft and half shaft fasteners. This will require putting the handbrake on and off and tightening 2 bolts at a time just like in the removal sequence.

Reinstall ABS brackets and mounting bolts, and reconnect the connector.

Tighten the 4 bolts and 2 nuts holding the differential into place.

 

Full guide with some photos here - http://www.yugobernie.com/images/SubFrame_Bushings/Guide/ES_Diff_Install.pdf

Thanks for that its an interesting read ill try bolting the front up first

Can you get a decent prybar in and lever the diff around:closedeyes: a bit to line the holes up?

Think I'm going to have to try. I'm abit worried as my subframe has been freshly powder coated

wrap a load of cloth or a t-shirt around the pry bar.

it may just be a case of making sure the diff is level. if it isnt then you would be trying to put bolts through at an angle.

maybe a silly question but have you tried turning the cups slowly to match against each hole? maybe they are offset and will only go back together one way.

 

just a thought mate

Still no luck spent a few hours on it again tonight. Managed to get 1 bolts in but im unable to move the diff to get the other bolt in. Becoming a joke really fed up with it now to the point im gonna give up

These are what I've now started to call '******* jobs' which generally are started, but then something doesn't go quite as simply as you thought it would and then when you eventually get round to asking advice all you hear is "Oh yeah, that's a ******* of a job"

 

I had a nightmare stripping the rear arms and hubs off my LWB the other year, and ended up taking to it with a grinder....and in the end I gave up on it

 

then I started the same task with the SWB the other week and though it took a few days (a few ******* jobs) they all worked out in the end *apart from the ball joint removal, which I have a solution for*

 

then I started on the drivers side rear and that time round it only took me 25 minutes from start to finish?

 

Like I said mate, looks like you've just got yourself a proper ******* job!

 

Don't give up mate :hammer: If in doubt...give it a clout!!!

I know it might not be easy,

but any chance of some pictures from further away, so as to get an overall view of the diff and surrounding sub frame from varying angles?

I am wondering if the powder coating my have distorted the sub frame itself.

i know exactly what the problem is there. ....... its not lining up!lol. just try to smile change your methods and don't spit the dummy. for now its laughing at you. but your time will come mate. good luck. oh i f***ing hate working on these cars!

grab a tea/coffee take a day off n think about it iv found this really helps on most jobs i cant get my head round...not really helpfull i know but

Thanks for your kind words guys....tomorrow night will be my 5th night of trying to get this bloody thing to fit. Trying all different ideas and ways. Spoke to Luke at the zed centre today and will be trying another way..hopefully the last. I'll take some pics if I don't win. Hopefully ill be celebrating

Good luck tomorrow night mate:clover:and keep at it:hammer:

Are they just not lining up or are they different widths apart? Have you taken centre to centre measurements of each to check?