I just recently blew my diff in my 2000 Civic, Poor Man's Type-R swap, GSR tranny. The car runs great, but keep in mind is an OEM rebuilt motor, so there is no major power here. I put in a new OEM open-diff 2 weeks ago from Synchrotech. A Honda Transmission technician and I did the work, everything was done and shimmed correctly, all OEM Honda parts, and Honda MTF. I baby everything, no launches, etc, and I noticed a leak from the outputshaft seal (how the bad diff started before). I tore the intermediate shaft out, and save that the "+" sign on the end of the diff has been sheared off... Again! I can't figure out what is happening! The intermediate shaft is straight, spins straight, but both times the tip of the diff sheared off (as did the rest of the old diff, along with all teeth broken off). However it does seem that the intermediate shaft does not want to bolt up without being pried about 1/4", which would definately stress the diff. Any input? BTW, there should be no reason to suspect bad mounts...

 

Sounds like youve found your own problem

 

I can't seem to figure out why this is so...

 

You will need to correct the intermediate shaft problem to prevent another diff failure.

 

If the shaft is indeed true you have an external misalignment of the intermediate shaft support bearing. the bearing mount is bent or it is the wrong application.

I've seen a few instances of people shimming the shaft to the block because they could not start the bolts in the block without the use of a prybar. Again also seen many blocks with threads missing for the support bracket.

Cast iron will fatigue and "flake" when the material is distorted, identifying a bent support bracket.

 

It is definately an external alignment problem, I'll try to line up another shaft and see what it does. Synchrotech is the ****!

 

I found the problem, the dude I got the swap off of used the wrong intermediate shaft...