g6civcx
07-17-2009, 11:58 PM
Note: I use standard Nissan terminology as outlined by the FSM for consistency. Nissan's terminology may not line up with industry standard. If there is any confusion, please ask me.
Please note that this is a tutorial and not a step-by-step how-to. I will assume that you have the knowledge of a Nissan factory-trained technician regarding such things as how to remove a diff, how to disassemble the diff carrier and install an aftermarket LSD, etc.
Therefore, I will only provide general guidance on the modifications required to perform this swap. The remaining details may be found at numerous sources, including this forum. If you find that I left something out, that's why.
As always, please feel free to ask me if you have any specific question.
=====================================
High-power S-chassis owners will find that the stock 4.083 rear diff ratio to be intolerable. The next closest rear end available from Nissan is 3.5. So if you find that 3.5 is still not adequate for you, this tutorial will guide you through how to install a Pathfinder R200 3.133 diff
Guys with highly modified engines, such as V8, Supra engines, high power RBs, etc., should read this guide very carefully.
The benefit with this swap is that you will be able to use all of your stock parts with very minimal modifications to the diff internals and chassis.
In my experience, the stock R200 diff can withstand up to about 500-600 ft-lbs for drag applications with slicks, and maybe a little more for roadracing applications.
If you're consistently putting down over 700+ ft-lbs, I recommend going to something bigger like an R230.
This is explicitly for an S13 with open diff. Other models may vary slightly but the general details will be the same. Modify the instructions to your own specific application as needed.
Parts needed:
* I will assume you have a fully functional S-chassis (S13/S14), including propeller shaft (connecting the gearbox to the diff), a stock R200 diff (open or VLSD), stock driveshafts (connecting the diff to the wheels), and everything is mounted to the stock subframe. Basically you have a stock-spec S-chassis drivetrain.
* You need an R200 from 2004-2007 Pathfinder 2WD. These come with VLSD and 3.133 ratio. The 2008 Pathfinder also has this R200 diff, but be aware that the '08 model also comes with R230 diff so it's easy to buy the wrong diff. Better to stick with 2004-2007 Pathfinder 2WD to be sure. Buy the whole diff from the companion flange to the side flanges. It's easy for the junkyard to remove the propeller shaft, the driveshafts, and drop the entire diff for you. Don't cheap out. Buy the whole thing.
* Buy an aftermarket LSD for your car based on the stock diff you have. I have an S13 open diff. I bought a Tomei 2-way for S13 open diff. Buy whatever LSD you want for whatever diff is on your car.
This is some shots of what mine and what yours should look like.
To the untrained eye, this looks like just any other S13 diff:
http://img208.imageshack.us/img208/4518/diff1.jpg
Looking closer, you still can't really tell the difference:
http://img194.imageshack.us/img194/8895/diff2.jpg
The driveshafts also look stock. These are the stock 6-bolt driveshafts:
http://img187.imageshack.us/img187/9164/diff3.jpg
http://img204.imageshack.us/img204/2337/diff4.jpg
The propeller shaft also look stock (other than the 1-piece design). For all intensive purposes, this is the stock propeller shaft.
http://img176.imageshack.us/img176/7427/diff5.jpg
http://img187.imageshack.us/img187/1630/diff6.jpg
The S-chassis diff and the Pathfinder diff look very very similar, and for all intensive purposes, they are the same. They have the same exterior dimensions. Both are about 11" from front to rear:
http://img240.imageshack.us/img240/5639/diff7.jpg
There is one HUGE difference. The Pathfinder 3.133 pinion is much bigger than the S-chassis 4.083 pinion. So Nissan made the Pathfinder carrier a bit larger to accomodate:
http://img27.imageshack.us/img27/2531/diff8.jpg
As such, trying to put the Pathfinder 3.133 pinion into the S-chassis carrier won't work. You need to use the Pathfinder carrier.
This picture is what's left after the swap is complete. Everything on the left is Pathfinder, and everything on the right is S-chassis:
http://img204.imageshack.us/img204/2500/diff9.jpg
I'll go through and discuss the swap with reference to the FSM:
http://img204.imageshack.us/img204/6812/diff10.jpg
Swap procedures:
1. Make absolutely sure that you have the right Pathfinder diff. The ratio should be 3.133. Rotate the companion flange and count the number of rotation of the side flanges for each revolution. It should be close to 3 revolutions and change.
2. Check the oil seals (front and side flanges) on the Pathfinder diff. Sometimes these diff sit in the junkyard exposed to the elements for long periods of time. If your oil seals are bad, replace them now while the diff is out of the car.
3. Go ahead and open the rear cover on the Pathfinder diff. Save the magnetic drain plug for use as the S-chassis filler plug (to help trap metal particles). The Pathfinder cover will not be re-used.
4. Remove the side flanges and bearing caps on the Pathfinder diff and make sure you don't mix up the left and right. Also make sure you keep track of the correct up/down orientation of the bearing caps for re-use. You will not re-use the 5-bolt side flanges.
5. Remove the differential assembly with ring gear attached. Make sure you mark the left and right side bearing outer races.
6. Remove the ring gear from the diff and don't lose any ring gear bolts. You will not re-use the diff.
7. Inspect what's left of the Pathfinder diff carrier very carefully. Assuming that your Pathfinder diff is good to go, you can start disassembling the S-chassis diff.
8. Follow the steps outlined in the FSM, remove the propeller shaft, the driveshafts from the side flanges, the cover nuts, and drop the entire diff from the car.
9. Remove the S-chassis diff cover. You will re-use this on the Pathfinder diff carrier.
10. Remove the S-chassis side flanges. You will re-use these. Don't mix up left and right.
11. Everything else left on the S-chassis need not be reused, but keep them sorted in case you need to.
12. Now open your new 1.5/2-way LSD and inspect verything. You will notice that when you try to line up your LSD with the Pathfinder ring gear, the LSD bolt holes are too small. This is because the Pathfinder uses 13mm ring gear bolts while the S-chassis uses 12mm ring gear bolts. You will need to carefully enlarge the holes on the LSD to accept the 13mm ring gear bolts.
13. Install the LSD with enlarged ring gear bolt holes onto the Pathfinder ring gear.
14. Install the asembly into the Pathfinder carrier with the correct side bearings, bearing races, and outer races from the S-chassis. This step you will perform as you would for any LSD installation. The only difference is you're installing the LSD onto a Pathfinder ring and carrier. If you have problems with the races then you will have to get custom parts. I didn't need to because my S-chassis parts fit correctly. Check the side bearing preload and install shims as per the FSM as you would if you were installing into an S-car.
15. Reinstall the Pathfinder bearing caps. Note that these are assembled at the factory and should be reinstalled in the correct left/right arrangement. If you have problems with this step make absolutely sure you're install the bearing caps correctly. If not, you will need to find another set or get your bearing caps custom fitted. I didn't have to because the Pathfinder bearing caps fit correctly.
16. Install the S-car side flanges and check anything that you would normally check with an LSD installation, like backlash, etc.
17. Install the S-car diff cover onto the Pathfinder carrier and apply silicone. Fill with LSD fluid to the filler plug and you're ready to reinstall the carrier back into your car.
18. Everything should bolt in just like a stock diff, with the exception that if you have an S13, you will need longer bolts for the ears. The S13 uses a solid diff mount and the s14/Pathfinder use a bushing that will require longer bolts. Alternatively, you can also go with the aftermarket solid diff mounts sold on this forum.
19. Bolt up everything, do a final check, and go for your test drive.
20. Enjoy your 3.133 rear end!!!
I hope this was helpful to everyone. I spent a lot of time on this swap and you guys benefit from my mistakes.
Please let me know if you find anything wrong, or if I overlooked something important.
Please note that this is a tutorial and not a step-by-step how-to. I will assume that you have the knowledge of a Nissan factory-trained technician regarding such things as how to remove a diff, how to disassemble the diff carrier and install an aftermarket LSD, etc.
Therefore, I will only provide general guidance on the modifications required to perform this swap. The remaining details may be found at numerous sources, including this forum. If you find that I left something out, that's why.
As always, please feel free to ask me if you have any specific question.
=====================================
High-power S-chassis owners will find that the stock 4.083 rear diff ratio to be intolerable. The next closest rear end available from Nissan is 3.5. So if you find that 3.5 is still not adequate for you, this tutorial will guide you through how to install a Pathfinder R200 3.133 diff
Guys with highly modified engines, such as V8, Supra engines, high power RBs, etc., should read this guide very carefully.
The benefit with this swap is that you will be able to use all of your stock parts with very minimal modifications to the diff internals and chassis.
In my experience, the stock R200 diff can withstand up to about 500-600 ft-lbs for drag applications with slicks, and maybe a little more for roadracing applications.
If you're consistently putting down over 700+ ft-lbs, I recommend going to something bigger like an R230.
This is explicitly for an S13 with open diff. Other models may vary slightly but the general details will be the same. Modify the instructions to your own specific application as needed.
Parts needed:
* I will assume you have a fully functional S-chassis (S13/S14), including propeller shaft (connecting the gearbox to the diff), a stock R200 diff (open or VLSD), stock driveshafts (connecting the diff to the wheels), and everything is mounted to the stock subframe. Basically you have a stock-spec S-chassis drivetrain.
* You need an R200 from 2004-2007 Pathfinder 2WD. These come with VLSD and 3.133 ratio. The 2008 Pathfinder also has this R200 diff, but be aware that the '08 model also comes with R230 diff so it's easy to buy the wrong diff. Better to stick with 2004-2007 Pathfinder 2WD to be sure. Buy the whole diff from the companion flange to the side flanges. It's easy for the junkyard to remove the propeller shaft, the driveshafts, and drop the entire diff for you. Don't cheap out. Buy the whole thing.
* Buy an aftermarket LSD for your car based on the stock diff you have. I have an S13 open diff. I bought a Tomei 2-way for S13 open diff. Buy whatever LSD you want for whatever diff is on your car.
This is some shots of what mine and what yours should look like.
To the untrained eye, this looks like just any other S13 diff:
http://img208.imageshack.us/img208/4518/diff1.jpg
Looking closer, you still can't really tell the difference:
http://img194.imageshack.us/img194/8895/diff2.jpg
The driveshafts also look stock. These are the stock 6-bolt driveshafts:
http://img187.imageshack.us/img187/9164/diff3.jpg
http://img204.imageshack.us/img204/2337/diff4.jpg
The propeller shaft also look stock (other than the 1-piece design). For all intensive purposes, this is the stock propeller shaft.
http://img176.imageshack.us/img176/7427/diff5.jpg
http://img187.imageshack.us/img187/1630/diff6.jpg
The S-chassis diff and the Pathfinder diff look very very similar, and for all intensive purposes, they are the same. They have the same exterior dimensions. Both are about 11" from front to rear:
http://img240.imageshack.us/img240/5639/diff7.jpg
There is one HUGE difference. The Pathfinder 3.133 pinion is much bigger than the S-chassis 4.083 pinion. So Nissan made the Pathfinder carrier a bit larger to accomodate:
http://img27.imageshack.us/img27/2531/diff8.jpg
As such, trying to put the Pathfinder 3.133 pinion into the S-chassis carrier won't work. You need to use the Pathfinder carrier.
This picture is what's left after the swap is complete. Everything on the left is Pathfinder, and everything on the right is S-chassis:
http://img204.imageshack.us/img204/2500/diff9.jpg
I'll go through and discuss the swap with reference to the FSM:
http://img204.imageshack.us/img204/6812/diff10.jpg
Swap procedures:
1. Make absolutely sure that you have the right Pathfinder diff. The ratio should be 3.133. Rotate the companion flange and count the number of rotation of the side flanges for each revolution. It should be close to 3 revolutions and change.
2. Check the oil seals (front and side flanges) on the Pathfinder diff. Sometimes these diff sit in the junkyard exposed to the elements for long periods of time. If your oil seals are bad, replace them now while the diff is out of the car.
3. Go ahead and open the rear cover on the Pathfinder diff. Save the magnetic drain plug for use as the S-chassis filler plug (to help trap metal particles). The Pathfinder cover will not be re-used.
4. Remove the side flanges and bearing caps on the Pathfinder diff and make sure you don't mix up the left and right. Also make sure you keep track of the correct up/down orientation of the bearing caps for re-use. You will not re-use the 5-bolt side flanges.
5. Remove the differential assembly with ring gear attached. Make sure you mark the left and right side bearing outer races.
6. Remove the ring gear from the diff and don't lose any ring gear bolts. You will not re-use the diff.
7. Inspect what's left of the Pathfinder diff carrier very carefully. Assuming that your Pathfinder diff is good to go, you can start disassembling the S-chassis diff.
8. Follow the steps outlined in the FSM, remove the propeller shaft, the driveshafts from the side flanges, the cover nuts, and drop the entire diff from the car.
9. Remove the S-chassis diff cover. You will re-use this on the Pathfinder diff carrier.
10. Remove the S-chassis side flanges. You will re-use these. Don't mix up left and right.
11. Everything else left on the S-chassis need not be reused, but keep them sorted in case you need to.
12. Now open your new 1.5/2-way LSD and inspect verything. You will notice that when you try to line up your LSD with the Pathfinder ring gear, the LSD bolt holes are too small. This is because the Pathfinder uses 13mm ring gear bolts while the S-chassis uses 12mm ring gear bolts. You will need to carefully enlarge the holes on the LSD to accept the 13mm ring gear bolts.
13. Install the LSD with enlarged ring gear bolt holes onto the Pathfinder ring gear.
14. Install the asembly into the Pathfinder carrier with the correct side bearings, bearing races, and outer races from the S-chassis. This step you will perform as you would for any LSD installation. The only difference is you're installing the LSD onto a Pathfinder ring and carrier. If you have problems with the races then you will have to get custom parts. I didn't need to because my S-chassis parts fit correctly. Check the side bearing preload and install shims as per the FSM as you would if you were installing into an S-car.
15. Reinstall the Pathfinder bearing caps. Note that these are assembled at the factory and should be reinstalled in the correct left/right arrangement. If you have problems with this step make absolutely sure you're install the bearing caps correctly. If not, you will need to find another set or get your bearing caps custom fitted. I didn't have to because the Pathfinder bearing caps fit correctly.
16. Install the S-car side flanges and check anything that you would normally check with an LSD installation, like backlash, etc.
17. Install the S-car diff cover onto the Pathfinder carrier and apply silicone. Fill with LSD fluid to the filler plug and you're ready to reinstall the carrier back into your car.
18. Everything should bolt in just like a stock diff, with the exception that if you have an S13, you will need longer bolts for the ears. The S13 uses a solid diff mount and the s14/Pathfinder use a bushing that will require longer bolts. Alternatively, you can also go with the aftermarket solid diff mounts sold on this forum.
19. Bolt up everything, do a final check, and go for your test drive.
20. Enjoy your 3.133 rear end!!!
I hope this was helpful to everyone. I spent a lot of time on this swap and you guys benefit from my mistakes.
Please let me know if you find anything wrong, or if I overlooked something important.