Again.

Yeah, my first thought was that i did something wrong too, but considering how gentle i was on the box for the first 1000kms, it can't be that. Didn't even go on the cruise to make sure it lived.
This one lasted 1271kms. Considering i only really started using half decent power about 200kms ago, and for the first 350kms of my rebuilt diffs life, i was averaging 7.9L/100km and purposely took ages letting to clutch out. So you know how gentle i was going on it.

What could be causing my LSDs to die?

For the history of the box, it's got 130,000kms on it and in the past has had a clutch explode in it. Is the box itself stuffed, and it's not worth rebuilding it again?
Are my tyres too grippy?
Am i just s***?

You are just S***. How the hell do you manage to snap not one but 2! Ralliart Diffs. I've never heard of anyone else doing it even with FI applications. I'd say your box has some sort of a problem or whoever rebuilt it did a dodgy.

Edit, Is your name 'LIFE'?

I would say that your gearbox builder is crap to be honest

Before you state for sure that the diff is stuffed, get it pulled apart and checked. Surely the builder did offer you some sort of warranty as well. Even if you did give it a hard time, there is no reason it should break after only 1000k. It may have a shorter life but 1000k is stupid

As above, I think your gear box builder has done something really wrong in the build, dont blame the diff or the box so fast, there has to be a reason both the first one and then the second has died

Is your Car Forced induction? how much power you making at the wheels? i thought the ralliart diffs were great :S

He doesn't want to cover it because it's 'driver fault', because apparently i'm retarded enough to get an LSD with 0kms and then dump the clutch everywhere.
It's getting sent to someone else to completely inspect and report, and maybe rebuild, and the previous builder will be getting the bill.

Diff is definitely stuffed, it has exactly the same symptoms as last time (same noises on decel) and a nice chunk of heat-discolored metal was taken off the oil drain plug.
Clutch has had a fair bit of heat in it, but i'm almost certain that's because i made sure to ride the hell out of it before i put any strain on the diff.

The only reason i'm wondering if the box might be crap is because of the last diff dying, the clutch explosion, as well as the fact that the 3rd and 5th syncros had to be replaced, which makes me think the box... Hasn't exactly had an easy life before i bought it, does that sound fair?


Now while all this crap is getting sorted out, can i drop a normal manual in it for a minute without issue, with the same clutch?
If so, 3.0 or 3.5?



Is your Car Forced induction? how much power you making at the wheels? i thought the ralliart diffs were great :S
Completely stock apart from wheels and an RPW short shifter.

Don't let my specific diff put you off Ralliart ones in general. I'm the only person in the world to have gone through 2x Ralliart limited slip diffs without extreme power levels at this point, AFAIK. Possibly without the 'extreme power levels' bit.

For starters riding clutches is just stupid. Please dont take offense but if your diff cant take normal use then there is something wrong. Add to this diffs dont get run in as such so if the box builder told you this he is clearly not confident of his work or the parts he sourced

When you heat up clutches you also ceack flywheels

Now you also say first clutch exploded. How did this happen

Again please dont take offense but i have my doubts that the box or the builder were the issue when you have exploded a clutch and then a ralliart lsd and then a second one given that i know a member here in vic who had a srd 3.0 box with a secondhand clutch and drives everywhere very hard. This guy knows 2 speeds. Flat out and stop and went through 0 clutches and 0 boxes despite some thinking these are made out of glass. He is also known for his launches

Completely stock apart from wheels and an RPW short shifter.

Before you typed this I was going to ask if it had a short shifter. I put one on my Ralliart and it was nothing but problems. Gear crunching, poor gear selection etc. It was terrible. I'm not saying this is your problem, but I would take it out if I was you.

Matt have any other NSW members been in your car whilst you are driving? If so, can they comment on your driving style? Either the gearbox is rooted or you can't drive a manual. TZABOY was putting huge amounts of torque through his gearbox running an evo clutch and standard LSD, with 230kw atw it was probably putting out over 400nm torque and he drives that thing ****ing hard and never had a problem with the diff in years

You shouldnt need to slip the hell out of the clutch either, thats going to generate unnecessary heat.

Just accelerate slowly, you should be able to accelerate very slowly and get totally off the clutch very quickly. Also if you are slipping the clutch alot at high RPM you are actually potentially transferring more effective torque.

Before you typed this I was going to ask if it had a short shifter. I put one on my Ralliart and it was nothing but problems. Gear crunching, poor gear selection etc. It was terrible. I'm not saying this is your problem, but I would take it out if I was you.
I've had no problems with my one, so far. Everything feels much better than with the normal one, especially considering i can actually get to drinks when i'm in 3rd or 5th now.
1st is a little bit hard to go back to, but i don't think that's necessarily a bad thing.
Plus, i've had no problems with the actual gears themselves. It's only diffs i've been having problems with.


Now you also say first clutch exploded. How did this happen

Again please dont take offense but i have my doubts that the box or the builder were the issue when you have exploded a clutch and then a ralliart lsd and then a second one given that i know a member here in vic who had a srd 3.0 box with a secondhand clutch and drives everywhere very hard. This guy knows 2 speeds. Flat out and stop and went through 0 clutches and 0 boxes despite some thinking these are made out of glass. He is also known for his launches
Clutch exploded before i got the car.

Diff died, pulled the box out and took the newly replaced exedy clutch out was the first time any of us heard about it. I'll grab some pics on monday for you and show you what happened 2 clutches ago.


I haven't been slipping the clutch too much, it's just when the diff was brand new i figured it was better to let it slip a little than to put much stress on the diff. Clutch has only had a little bit of heat in it.

like mal said, diffs dont need to bed in. if he has asked you to drive slowly for the first thousand k's, he has no confidence in the parts and work he has supplied.

also, have you driven the car since the diff went? this could be causing you gearbox issues because that chunk of metal you found on the drain plug may have been floating around in there while its been driven. which can cause heaps of other issues.

Are you even sure it has an LSD? I know it was advertised with one but just make sure of these things you know..

Handling is completely different to my old Auto, so i know it has the LSD.

I don't find my RA any different to my vr-x for handling... i mean i don't go around corners while flooring it or anything though.

Yeah the diff breaking is a symptom. Surely a competant transmission specialist could diagnose why this is occuring; eg could be alignment issues etc. Would be worth looking at the vibration characteristics of the gbox during operation.

I don't find my RA any different to my vr-x for handling... i mean i don't go around corners while flooring it or anything though.
Depends if you've driven your Ralliart on crap tyres yet.

With the (barely legal) tyres that were on it when i first got it, it still managed to grip at WOT in 1st and didn't just light up coming out of a corner. Even my Auto with good tyres would light up a tyre in 1st if i accelerated too hard while turning.


So the general consensus is that the build was done badly?
We'll know soon, box should be going somewhere soon enough and everything should be known then.

IIRC, my clutch is 230mm. Can i just grab any old manual box and pop it in for a minute while the box is getting done, with the same clutch and just run that for the few weeks it'll take?
Nothing Ralliart specific, is there?

My only recommendation is to buy a Quaife for your next diff, they offer a lifetime parts warranty including track use.

You'd probably still have to cover labour but save you getting a whole new diff if you somehow managed to break it.

What were you actually doing in terms of your driving, when both these diffs went?

For eg were you dropping the clutch off the lights both times, etc?

Might allow some more specific feedback.

Alright, so i heard back from the guy i sent it to down in Sydney today.
Apparently, either the crown or pinion (can't remember which at the moment) was new - while the other was not. The new part chipped the tooth off the old one, causing the deadness.

Currently rocking a 5 speed out of a TL, so all's good while he goes right over the box and makes sure it's ready for a new diff.

I know when I did my diff, the damage was rather extensive. The spiders gears were shattered, the crown wheel was chipped, the pinion was chipped, and there was a shitload of shavings and teeth in the trans casing.

You are actually better off having the LSD installed on the TL box instead as you know the gears are good. The only difference between a standard and RA box is the LSD. If you're after even more acceleration, you could also install the LSD in to a 3lt box (This will give you a shorter first gear, and 3.9 diff ratio as opposed to the 3.7 -- In short, more acceleration, however also more revs I think there is around 100rpm difference between them and 8km/h @ 6000rpm in first gear).

All i can say, is i've permanently disabled my TCU, as TCU will smash your lovely LSD to pieces at a very quick rate.

That's why Traction Control was never available for the ralliart manuals.

Traction control wasn't available on any of the manual equipped cars was it?

How does traction control smash LSD's? It just regulates motor output .... I have both

All i can say, is i've permanently disabled my TCU


Can you please detail how you did this as i would love to be able to do this to mine,

thanks

Can you please detail how you did this as i would love to be able to do this to mine,

thanks

Easiest way for you is to install a TJ 4sp tippy ECU without TCL (TJ Series 2 Exec should do just fine) and unplug the TCL ECU.

How in gods name does tcl smash diffs. Unto this moment I thought I had read about every crazy claim made on these forums about magnas but then I read this troffle. Now please excuse me while I go and rebuild a few hundred manual diffs ready for all of these people with manual conversins will need

As for the statement about ralliarts not having tcl, this just in, no manuals did

TCL will help the diff if anything.......

How in gods name does tcl smash diffs. Unto this moment I thought I had read about every crazy claim made on these forums about magnas but then I read this troffle. Now please excuse me while I go and rebuild a few hundred manual diffs ready for all of these people with manual conversins will need

As for the statement about ralliarts not having tcl, this just in, no manuals did

TCL will help the diff if anything.......

Heating your fuel gives performance boost. bahahaha
Guy above is umm.. right.

How in gods name does tcl smash diffs. Unto this moment I thought I had read about every crazy claim made on these forums about magnas but then I read this troffle. Now please excuse me while I go and rebuild a few hundred manual diffs ready for all of these people with manual conversins will need

As for the statement about ralliarts not having tcl, this just in, no manuals did

TCL will help the diff if anything.......

lol .... When I was getting my Quaife done in the auto, a Mitsubishi mechanic told me I couldn't put one in an auto coz it wouldn't last & would explode! Maybe Snow works at my dealership???? lol