I've posted about this issue in another forum and I'm trying to get some more insight here as well.
I'm experiencing a "loud clunk" that is occurring inside my 4th gen differential. It's centered around where the driveshaft connects to the pinion. This clunk is replicated when downshifting without a revmatch in low mph or by attempting to launch the car (2-3k steady). In both instances it can be heard audibly (like a loud bang). It can also be heard when coasting through 3rd-4th gears as the car is moving (way less audible than the other two instances but still there).
The car just got a new clutch setup back in March (Diamond Stg 2 w/ 15 lb flywheel), 95A Revshift Flex Disc, 95A Revshift Rear Cradle & Trailing Arm Bushings, Original KARS Stage III Kit, DSS Anti-Wheelhop Axle Bars.
It also has Creative Steel Motor Mounts & Trans Mount. It had a Creative Steel Diff Bushing that helped with the clunk but it eventually came back. It has since been replaced with a Revshift 95A Diff Bushing over last weekend. Now originally I also thought that the clunk might have been driveshaft related but I figured I'd wait until I replace the diff bushing again and report back.
When going through the car I found out that my Creative Steel Trans Mount isn't looking too good, it's still there but I can feel the polyurethane deteriorating. If you look closely at the picture, you can see it's beginning to shift slightly off the mount.
There was some random grease that was scattered around the diff pinion seal and heat shield. Discovered that was coming from the driveshaft end. Looks like I'm going to need a driveshaft regardless...:halo:
Drained the fluid, some metal shavings on the magnet, nothing out of the norm though. Mechanic used a camera to see if we can find any chipped teeth or carnage inside but there was nothing visible outside the norm.
The differential had to come out completely because the old CS bushing still had to be pressed out. Last time I rented the CS tool that allowed us to keep the diff in the car. This time we improvised with a drill bit, air chisel, and an electric hacksaw for the sleeve.
We also took out the pinion gear just so we could get a better view at what the camera wasn't able to see. Nothing other than wear for the car's mileage. Do I have severe backlash? Probably, I honestly don't know what to think anymore, maybe I should accept the fact that it's German garbage and move on....
I had some light whine before, now it's more pronounced. Is the car better with the new Revshift diff bushing? Absolutely! Did it completely fix my problem? No, it appears that I have more problems than a new diff bushing would fix. :eek2:
Suggestions are welcome (I already know a V2 would fix everything but it's too far out right now)
Anyone have experience with an internal noise in the differential like this?
I'm experiencing a "loud clunk" that is occurring inside my 4th gen differential. It's centered around where the driveshaft connects to the pinion. This clunk is replicated when downshifting without a revmatch in low mph or by attempting to launch the car (2-3k steady). In both instances it can be heard audibly (like a loud bang). It can also be heard when coasting through 3rd-4th gears as the car is moving (way less audible than the other two instances but still there).
The car just got a new clutch setup back in March (Diamond Stg 2 w/ 15 lb flywheel), 95A Revshift Flex Disc, 95A Revshift Rear Cradle & Trailing Arm Bushings, Original KARS Stage III Kit, DSS Anti-Wheelhop Axle Bars.
It also has Creative Steel Motor Mounts & Trans Mount. It had a Creative Steel Diff Bushing that helped with the clunk but it eventually came back. It has since been replaced with a Revshift 95A Diff Bushing over last weekend. Now originally I also thought that the clunk might have been driveshaft related but I figured I'd wait until I replace the diff bushing again and report back.
When going through the car I found out that my Creative Steel Trans Mount isn't looking too good, it's still there but I can feel the polyurethane deteriorating. If you look closely at the picture, you can see it's beginning to shift slightly off the mount.
There was some random grease that was scattered around the diff pinion seal and heat shield. Discovered that was coming from the driveshaft end. Looks like I'm going to need a driveshaft regardless...:halo:
Drained the fluid, some metal shavings on the magnet, nothing out of the norm though. Mechanic used a camera to see if we can find any chipped teeth or carnage inside but there was nothing visible outside the norm.
The differential had to come out completely because the old CS bushing still had to be pressed out. Last time I rented the CS tool that allowed us to keep the diff in the car. This time we improvised with a drill bit, air chisel, and an electric hacksaw for the sleeve.
We also took out the pinion gear just so we could get a better view at what the camera wasn't able to see. Nothing other than wear for the car's mileage. Do I have severe backlash? Probably, I honestly don't know what to think anymore, maybe I should accept the fact that it's German garbage and move on....
I had some light whine before, now it's more pronounced. Is the car better with the new Revshift diff bushing? Absolutely! Did it completely fix my problem? No, it appears that I have more problems than a new diff bushing would fix. :eek2:
Suggestions are welcome (I already know a V2 would fix everything but it's too far out right now)
Anyone have experience with an internal noise in the differential like this?