Rebuild and upgrade the Corvair differential for MORE POWER

[@sethemerson885]

If converting/relocating the internals from a 65 differential to a 66 Differential housing, be sure to verify the overall length of the pinion shaft. It is shorter (by a little bit) on the 66. If you want to use a 65 pinion shaft, you should shorten it to the 66 length. I think it had already been done on this unit. If you fit the 65 shaft at full length, it will kill something in the mix.

[@FlawlessPlanGarage]

Thanks, Seth!

[@trevorseals6588]

I was a machinist for a while and your flawless plan for getting the broken bolt drilled out was still something I’ve never seen before and I gotta say I’m impressed

[@FlawlessPlanGarage]

Even a blind squirrel finds a nut!

[@haroldlamble5163]

I remember when both my brothers bought themselves new corvairs . One was burgundy one was tan . They were a lot of fun . Your story brings back fond memories thank you.

[@FlawlessPlanGarage]

Thank you!

[@amazeddude1780]

Arrrgh! You read the shop manual, you followed the steps, yet you found a creative way to pooch regardless! Outstanding!

[@FlawlessPlanGarage]

It's sort of my thing! Except for the reading instructions part, usually I only do that after the fact....

[@andyjones357]

The sound of a classic car start up after all the work and redo of what you did blood sweat and tears later that start up sound is the sweetest payoff

[@FlawlessPlanGarage]

Even better when that startup isn't accompanied by a fresh puddle of oil! I mean, that's what I've heard. Haven't gotten to experience that.

[@markbartlett6287]

My first car, back in '81, was a '65 500 coupe. I didn't realize until watching this video that there were so many differences between the '65 and later years.

[@annelarrybrunelle3570]

Hint to remove broken bolts: put a carbidr burr in a Dremel tool and make a mark as near center as you can. Drill with a small drill, maybe 1/8. then use the Dremel tool to recenter the hole as needed. Drill somewhat bigger. Try an EZout. If that doesn't work, or you don't want to try, keep drilling bigger, alternating with the Dremel tool until you have just a shell of threads. Then use the Dremel tool to grind the interior threads longitudinally just enough to break the shell of threads in 3 places. You can now tap the fragments loose with a punch and pull them out with a magnet or needlenose. Chase with a tap. Sound complex and time-consuming? It's not. I used to extract manifold bolts or studs from cylinder heads this way (yes, on the bench; it was an auto machine shop) in about 5 minutes each. You put new studs in with Loctite and they won't rust in place. Hope this helps someone. (BTW, Dremel makes a wee carbide burr with a sort of reverse teardrop shape that does this REALLY well. That's why I said "Dremel" instead of "die grinder".)

[@FlawlessPlanGarage]

If you've ever gotten an easy out to work, you're a better person than I! I've broken at least 2 full sets and maybe gotten one bolt out for every 6 easy outs I've had to drill out.

[@JMassengill]

i had a 64 greenbrier that i removed the engine to try and replace the clutch and broke the throwout bearing carrier on the trans/diff removing the engine. (if I removed both engine/trans/diff together it wouldn't have broken) I was in my 20's at the time and knew nothing about setting up a diff so I gave the van and a shed load of parts away for the price of "just get it out of my yard" nice diff rebuild. great work, great video

[@FlawlessPlanGarage]

Easy to break that throwout bearing carrier "snout" when installing or removing the engine for sure! The aftermarket parts available now are reinforced and stronger than the originals.

[@butziporsche8646]

When I was a kid, I worked for Cal's Corvair Service in Garden Grove and everybody wanted the Saginaw transaxle for kit cars (I had a 63' Monza Spyder and a Greenbrier). A 110 with a Powerglide was pretty anemic off the line. Great cars though.

[@FlawlessPlanGarage]

Most Corvairs are pretty anemic by modern standards, but they remain quite enjoyable to drive regardless!

[@keithhill9138]

That is so funny that you left the seals out! We all make mistakes when we are not doing it all the time!!!

[@kisoia]

Thanks for the video - at least the seal was easy to install without complete disassembly. You will love that "slip on" bearing cone the next time you are setting up one of these differentials :)

[@patrickshaw8595]

Brings back memories. Had a bunch of these cars. Did every mod you could think plus using an Onan CCKW up front driving a Sullair screw compressor making 30 psi boost. When shifted roughly the '66 Saginaw trans I made a dog-box out of (home shop made face plates) held up fine but it would strip all the teeth off the pinion gear. 3.27 sets would take more torque before stripping (Duh = bigger pinions). Beat a dozen V8-vairs drag racing. I really did find a replacement for displacement and it was 7-1 compression and a nice intercooled 30psi of boost. Bach then the only possible carburetion for such a thing was a propane mixer in front of the Sullair. I had three separate flash arrester screens and popoff valves between the engine and induction piping - didn't want to find out what it would do if it backfired. Oh - and shopmade tool steel needleless u-joints, too. A stock 140 hp Corsa was good for about an 18 second quarter mile and I got a couple of mine to run in the 10s consistently. In the 80s.

[@FlawlessPlanGarage]

Wow, that is moving!

[@patrickshaw8595]

@@FlawlessPlanGarage Dad had extensive air-cooled insight from his time at Pratt Whitney and his identical twin brother was Chief Engineer for Outboard Marine Corp. The car figured heavily into my mechanical engineering degree in '75. "Corvairs - like motorcycles- should have all-alloy air cooled engines forever and ever, Amen." If you ever want to get crazy with the car I know where you can get 4T80 transaxle and an O-720 Lycoming flat-eight. "Sure! WE CAN MAKE THAT WORK !" lol...

[@dennissnelling5555]

I use an expandable freeze plug to check the rolling torque. Just push in and tighten the nut and your able to check the torque.

[@FlawlessPlanGarage]

Good idea!

[@tOxIc_TrEaSuRe]

or maybe one of those plumbing test plugs

[@ThatGuyFromArizona]

In my business we had the luxury of an EDM machine when we needed to remove broken bolts from Ford 460 cylinder heads without removing the heads. I do like your concept of the guide plate.

[@FlawlessPlanGarage]

An EDM machine would be a dream to have handy!

[@willieshaw2522]

As a FYI - if you do this again in the future, you were reading and adjusting the pattern on the coast side of the ring gear teeth. You normally read and adjust the pattern depth on the drive side with the pinion shims, then adjust the coast side with backlash as necessary. Getting the drive side correct is usually considered more important, so you don't have constant noise going down the road.

[@FlawlessPlanGarage]

Thanks! I did read the pattern in the drive side but had terrible trouble filming it well, I should have been more clear in my comments

[@craigmonteforte1478]

My guess for Touqing the Pinion it would fit clamped into must Vintage Vises you spoke about those Old Timer Farmers and Such that was always one of my Dads Resources in our Garage he used that to Compress American Muscle Car CoilSprings and in combinations with different Sockets we used it like a Arbor Press for installing and Removiving all kinds of Bearings and pressed in parts we often used heat and Cold by setting parts in the Kitchen Refridgerator and Torching the other parts with a Propane or MapGas flame we also always had many homemade Puller Jaws that could be sealed in and out of a Typical 2 or 3 JawConventiol Puller my Grandfather was a ProfessionalWelder and we had a few Machinists in the Family that would make us Customparts for whatever we were working on BTW i grew up inSouthFlorida and did a lot of Boat repairs and Restrations plus we restored Antique and Vintage items

[@sandymilne224]

Loved the detail of the rebuild. Thanks

[@FlawlessPlanGarage]

Thank you!

[@1RAYGC]

Back in the day installed a Chevy 350 in my 66 Corvair convertible using the Crown transmission input shaft.

[@victorriceroni8455]

I am getting tickled watching Joffery Baratheon making faces behind you.😅😂

[@classicstangbrn8964]

Boy this brings back memories, done a bunch of those.

[@Friedbrain11]

To strengthen the case you could have gotten the stiffer cover for it and it really helps. Ofc you have to send the case without internals to the person doing the work but it is worth it. Had a differential(posi) that was beefed up and had all the good stuff done to it including the cover and it could take 350hp+ through it.

[@FlawlessPlanGarage]

True enough... my warmed over 140 will never threaten this diff with that much power, though

[@mrpontiac83]

63 Tempest has a similar transaxle as you probably know. Uses Corvair 3 spd or 4 spd transmission with bigger differential. Tempest differential has shims on the removable end cap so much easier to set up. Was fun to see rebuild process for corvair

[@FlawlessPlanGarage]

Cool, knew they were similar but have never had my hands on any Tempest stuff

[@bryanturner683]

Seems an expert witness got two kids off a murder charge because of the Tempest Trans axle???????

[@Friedbrain11]

@@bryanturner683 Heheheheh :)

[@DumbCarGuy]

I pulled my 65 corsa tranny out and rebuilt a 66 tranny. I didn't realize they were different. Thank god i had the doner car. Things like the 6' long shifter arm were different lengths, the top cover was different and a few other things I don't recall.

[@jamest.5001]

Fresh gear oil, and fresh kitty litter! 😆 Using used kitty litter sux! 😙, Haha, especially laying in it!!

[@davidbutton3111]

Not to confuse the issue, but remember the photos in the Corvair service manual were from a "big" car differential so they are backwards for a Corvair.

[@Jason-fe2px]

Great video, I love working on my corvairs

[@paulgrimm]

I’m missing my 62 convertible. The car of my youth

[@geraldbrakefield3874]

your kid sure had fun in the opening monolog

[@keithstudly6071]

Oh the smell of leaking gear oil. I remember it took at least 3 days to get the smell out of my hair. Yeah and I had the transmission rebuilt and the diff gone through the first time I did the job. Got it on the engine and filled it with oil. Came back the next day and found 4 quarts of oil on my floor because the guy who did my transmission had not put a new gasket between the trans and diff. He had just bolted them together to make it easier for me to take them home. OH, those were the days!

[@kirstenspencer3630]

Please build / buy proper jack stands. Nice build. Vairy helpful journey you took us on.

[@brants2000]

Well, I learned something new. I've never seen someone walk through all of the steps to overhaul a differential. Lots of flexibility to adjust the gear pattern, I wonder if that is the same for newer differentials today?

[@FlawlessPlanGarage]

Some are more or less difficult, but basically, yeah. If there's a ring and pinion, there needs to be some adjustment to get them to interface correctly.

[@jamesgeorge4874]

AAM 10.5 and 11.5 inch do have threaded adjusters like this, Toyota truck rear diffs also, most 1/2 ton pickups use shims to set the the ring gear side clearance.

[@dougheath7072]

Aftermarket vw was called a beefadiff made it Bullittproof 2spider gears and a cross

[@TairnKA]

I read somewhere, if doing a Crown conversion (Corv-8), it's possible to rotate the transaxle 180 degrees around the axles and the ring gear to pinon contact patch will be good (stronger gears recommended for first gear use). ;-)

[@bryanturner683]

Not sure you are correct. The Crown conversion connects directly to the transmission.(uses a adapted input shaft) I cant imagine you could rotate the transaxle and have it connect to the tranny without major work??? Corvair is Engine/Transaxle/Tranny, Crown is Engine , Tranny, Transaxle.

[@TairnKA]

@@bryanturner683 Its been decades since reading it and to be honest, recently I believe I've misread it, but it sounded so convincing at the time. ;-)

[@bryanturner683]

@@TairnKA It may be correct, I had a crown and it just doesnt make sense to me.????

[@oddcarsandbaddecisions]

The kid is killing me!

[@PaulHigginbothamSr]

My idea was to drill the hole at the proper place where the offset hole was. Then drill the hole in the correct place tacking the plate on top just like he did. Then to drill the hole through the old bolt to put on a left handed drill so it is spinning backwards in the old hole but drilling just fine but not walking off it's spot because the drill flights are turning backwards.

[@keithhill9138]

That part is called a front bearing retainer!

[@MikeMcAuliffe-g2f]

Your son is ready for stardom!

[@jamest.5001]

You may be able to drill. Out that bolt, then use a Dremel, to grind it to the point the threads can be picked out! Maybe a tiny end mill. If it gets too bad, drill a big hole then tap it, screw the bolt in, red lock tight it in. Cut it off, then drill and tap the correct size, drill a tiny hole between the threads, and drive a tiny pin in the hole, cut smooth, and peen the end with a punch, do it should never come out, then drill and tap a hole for the proper size bolt, they make kits that do the same thing. But using a bolt is probably cheaper..

[@FlawlessPlanGarage]

I was glad that my "drill guide" worked and I was able to heli-coil it!

[@jettrucker3177]

The poster made a "special" temporary bearing for the front of the pinion shaft for choosing the shim under that bearing. I never saw in the video where he replaced that temporary bearing with a proper (press-on) bearing. Maybe I missed it. If not (he's running with the reamed-bore bearing), I'm afraid he's in for trouble sooner or later.

[@FlawlessPlanGarage]

Hah! I make lots of mistakes, but not that one, at least this time. The "special" bearing is safely in the custom Corvair tools drawer, and the fresh bearing is in the diff.

[@jettrucker3177]

@@FlawlessPlanGarage DID you show that step in the video? If so, I just must have missed it. I have (successfully) rebuilt diffs in my 1961 Monza and my 1966 Corsa including installation of Clark's double-spider kit. Still driving the Corsa all over South Florida (Land of No Hills, and damn few curves as a result). I goof AT LEAST as much as you.

[@chrisn.4136]

Love your sidekick:)

[@FlawlessPlanGarage]

Thanks! He's not much help, but at least he's expensive :)

[@staljans]

good video, i'm inspired to tear mine apart..then i think 2 self, no , it works, don't do it, leave it till it starts to make noise. engine almost together, having issues with the bigger oil pump gears.. do you have any vids on that area? also i noticed the suspension [clarks improvement on geometry] your strut rod is on the upper hole, the one i got has only a lower hole. how is your handling? have you tried to put strut rod on the lower hole in the rear end brace?

[@RadioReprised]

Is this upgrade just for peace of mind? I had every model of Corvair ever built and sent 180 HP through one Trans and a set of Paddles Dragracing with no issues. Back in the Day, the biggest hassle was no silicone based O Rings and the rubber ones failed constantly! Love to watch any Corvair content you put out!

[@FlawlessPlanGarage]

Yeah, it's overkill for my slightly warmed-up 140, for sure. I have plans for a future Corvair project using a different engine with about 2x the power, but that probably won't include the Corvair transaxle.

[@63turbo]

Having broke the spider gears on a completely stock 140, simply by dumping the clutch on dry pavement, no, it isnt simply for peace of mind. It is for peace of mind when being bad!! Shock loading is what kills differentials, not "hp" by itself. If you shock the differential hard enough, you will kill it and the first thing to go is the spider gears. The next thing to go is the posi traction cover... I broke one of those from a hard shift at around 15psi of boost. It is real easy to keep the stock differential from dying by being careful, but they are easy to break when having some fun!! I set my current differential up with 4 spider gears and deleted the posi and used the machined throw-out bearing snout as was used in this video... I think I put that diff in 20 years ago and still works just fine. I cant remember how many differentials I had toasted for one reason or another prior to that.

[@craigmonteforte1478]

you forgot to mention the Installation instructions in those Manuals Installation is the same as removal inReverse Order my Dad and i did a lot of Wrenching together on Antique British Sports Cars (his and mine ) and the Vintage Family Volvo Wagons (his and my Moms ) he drove the Standards and Mom the Automatics me i took whatever had gas in it LOL ironically the Wagons had Positraction and they were fun as hell to Drift with ! fast foward to modern times many people younger than myself do Convert or Upgrade the Power Plants to build them into Competion Drift Cars ? Not my Thing but i think it’s funny to watch and hear them talking about it

[@carlcarlamos9055]

Off topic here, but maybe you might know. Is it possible to swap the later Corvair suspension for the earlier swing axle suspension? Thanks and take care.

[@125AXer]

A year late... I understood that the reason for this work was a bad bearing, but I didn't see any during disassembly... Was there residue/evidence in the bottom of the old differential housing? If there was, did you do anything to clean out the transmission? The Diff and Trans have a common gear oil system, so a failure in one carries bits to the other.

[@JDWard-Jeepster]

What did you do about the cracked boss opposite the one with the broken bolt?

[@FlawlessPlanGarage]

Maybe it was a deceptive mark.... the boss wasn't cracked.

[@spenceradams2908]

My diff doesn’t have that boss for some reason any idea if just putting the drain on the slope part is a bad idea

[@FlawlessPlanGarage]

The casting would be a lot thinner without the boss - your call on the risk!

[@jamest.5001]

I have a corvair it has the 2spd glide! I'd like to some days either swap to a 3.8v6, or , LS4, that was not a bad looking car design, it would been nice if it was front engine, and kinda shorten the rear a bit, I like the 4doors better for that reason, it would be awesome if they built a electric new car designed after the corvair, it would be awesome! Similar to the 2010 Camaro,

[@kisoia]

There have been several 3.8 v6 swaps, check out the forum at corvaircenter.com/phorum/list.php?1 Also see John Reynolds youtube channel he is putting in a transverse LS4 kzbin.info

[@v.e.7236]

Been debating on this upgrade for my '65 140. What kind of price tag goes w/ the machine work you had done? Looks like the main work was the hole in the carrier for the second dowel pin for the new spider gears. Seems like good insurance for drive train longevity and integrity. Thanks for the walk through.

[@FlawlessPlanGarage]

I think there's a bit to the machine work - a custom block for the 2 shafts, modifying the carrier, magnafluxing the gears, setting up the right shims on those gears, etc. You can contact Regan for his current prices - his email is in the video description. Clark's Corvair parts offers the service as well, and their website is also in the description. I agree it's nice peace-of-mind. Probably overkill for me since the car won't see the track much more, if at all, but it should be bulletproof now.

[@ricknorris6943corvair]

You are not the first nor will you be the last to make those mistakes. GG!

[@FlawlessPlanGarage]

Plus I had to sub in my nephew since I don't have a swanky air-over-hydraulic cylinder on my engine hoist! I'm roughing it over here!

[@ricknorris6943corvair]

@@FlawlessPlanGarage Ah feel yer pain Bubba....

[@ericfredrickson5517]

Didn't Chevy build a 4-spider limited-slip diff?

[@FlawlessPlanGarage]

Limited slip yes, marketed as Posi-Traction. 4-spider (for the Corvair), no.

[@timrussellguitar1516]

Next time try using an end mill. It doesn’t care if the hole is off center.

[@FlawlessPlanGarage]

I see you've wildly over estimated the tools I have available in the garage! :)

[@ervie60]

At the risc of coming off as pedantic but after all this work I think you missed some vital points regarding these tapered roller bearings. What you refer to as a bearing is a cone. The part you referred to as outer race (correct terminology btw) is called a cone. Cup and cone form the bearing. I do hope you took out those cups while all was apart cos cup and cone need to run in as a unit. Worn out cups paired with new cones..well won't work as long or as well.

[@joycemusgrave161]

😅😅 Paul here. That makes me feel better when I screw up. Also no colorful language.

[@FlawlessPlanGarage]

If you like honest mistakes, you'll love this channel :)

[@justintreadway]

What are the Corvairs front bucket seats from?

[@FlawlessPlanGarage]

A 1985 Mazda RX-7. I loved them in the RX-7, but they are cripplingly uncomfortable in the Corvair - I did something wrong when making the seat rails and the angle kills my back. I have a set of BMW seats with integrated shoulder belts as a future Corvair upgrade when I get the time.

[@teashea1]

What a good kid

[@FlawlessPlanGarage]

And apparently a natural comic - the next 12 years or so could be interesting!

[@timothymoroney3561]

Did I miss something ? I thought you have a 140hp 'vair engine there ?

[@FlawlessPlanGarage]

I do. But it's modified, and could theoretically put as much as ONE HUNDRED HORSEPOWER to the wheels, and that warranted an upgrade. Or maybe I was looking for an excuse? :)

[@MrLamontp]

Your son is great

[@donaldconnolly220]

you should open a shop.....id pay you to do this. job

[@bikerbillindiana7113]

Mistakes are made every day. Takes a good man to admit it. I do it all the time

[@larezcorvair6551]

My GOD I wish we was neighbors 😩😩😩😩

[@FlawlessPlanGarage]

I don't think all of my neighbors share that feeling :)

[@mikerichards6311]

😳🤪👍👏🏻👏🏻👏🏻

[@franksprecisionguesswork501]

Disappointed you didn’t show details of the spider gear machine work……..

[@FlawlessPlanGarage]

He did such a nice job pre-assembling everything I didn't want to take it apart - but I agree, I wish I had opened it up and shown it as well.

[@Friedbrain11]

Any manual that doesn't have some smudges and dirt from being used isn't a manual LOL

[@БольБоль-к9н]

Hi, my name is Mihail, i live in Ukraine- I won't the same car in a future. Can you give advice? Thanks for watching!)

[@063317Art]

Another speeded up video to the point of not worth watching. i quit @ 2:19

[@williamnichols429]

Turn the F-ing music down!!!!

[@markbartlett6287]

Easy there, but yeah, I was constantly adjusting the volume between the talk and musical sections.

[@robertpulliam9973]

Your dam music is too loud

[@FlawlessPlanGarage]

I'll try to keep all water-barrier-related-music at a more reasonable volume in the future!

[@lkmsl]

You are not stupid !

[@FlawlessPlanGarage]

Highly debatable!

[@Michael-y6h9p]

I just started watching bad idea. In my opinion. I hope it works. I'm going to continue watching. I watched it. The Healy coil worked OK but I would have taken a die grinder. And ground the bolt away until it was on the inside of the threads. Then you could use a die grinder And remove the rest of the bolts without drilling and putting in insert.

[@Michael-y6h9p]

Oopsie it happened to the best mechanics plus it's still in the shop getting fixed so it technically is oh shit😅