Ricks project AE85 (Back together with dyno results)

[Rick]

Its nearly been on the road for two months now and I am still trying to get use to it. I have been trying to drive it atleast once a week to iron out the bugs and to see if I can break anything, which Iam still working on.

I got pissed off at looking at the paint coming off my exhaust manifold so I pulled that off and will send that into get painted in a metallic ceramic coating.

From the word go the LSD in the diff was not working as it should and Hilux LSD's from the factory arn't that flash to start off with. It had a leak from the oil seal and the diff also started to make a rumbling nosie on deceleration and after a few 0-100 test runs it got noticeably louder, I had initially replaced the half shaft bearings, but didn't touch the diff head, its as it was from the Surf.

So I pulled it to bits and decided I would replace all the bearings and get the LSD reshimmed. I had a spare LSD from a early 2000 model Hilux that I will get reshimmed, having done less kms and in better condition than the Surf one. So it was a matter of removing the crown wheel and installing it on the newish LSD.

[Rick]

I got the diff head rebuilt and ended up using the earlier model LSD as they have more clutch plates in them compared to the newer ones. Filled it with the Redline oil which I think is the same price as gold, cost me over $100NZD to fill a 2.8L diff



I got the manifold back from the painters, looks good hopefully the paint will stay on there.



I also took the car if for a dyno power run. I went to ST HI-TEC LTD, professional looking work shop, had a few hundred thousand dollars worth of GTR Skylines being worked on when I was there.





I dealt with the Managing Director Soichi Tate (Japanese) top bloke.

I explained to the guy would it be alright for me to leave the car running while it is hooked up to the dyno as if I turn it off and back on again it has a power cut at around 5000rpm, he wasn’t happy with that, so when the first power run was done the power dropped off just after 5000rpm. I explained further to him that it’s a common fault with these motors and after a period of time the fault clears and it makes power all the way to the redline, he persisted and after ten or so runs to the redline and over 20kms clocked up on the dyno the fault cleared and it made 111.5kw’s at the wheels. So I was quite pleased with the result and if wasn’t for Soichi perseverance I probably would wouldn’t have got that result, it also helped that he owns a AE86, good man.





The dyno graphs below show the power cut runs in RED and the run without in GREEN.

[Eircamae86]

Just read the whole thread again, brilliant build, any more updates?

[jdm86gtz]

Super neat install. How much room have you between the charger and the chassis leg?

[ae86driftmaster]

KW is the same as HP right?

here is mine's bone stock..
i dont know my new hp yet..almost finished building gze

1st run w/no s/c
2nd run with s/c

[doggy]

1 Kw is 1.34 Hp... So no - its not the same

[ae86driftmaster]

oooh ok so....its 149hp..

[Rick]

Time for a bit of an update.

Late last year I took my car around a new race track called Hapton Downs, I had a good time there, apart from on my last lap of the day on the cool down lap on the second to last corner my clutch died and had to get the car towed home, but it was worth it.

























The cause of the non working clutch.





New clutch




A noise has seemed to have developed since I replaced the clutch but it could have appeared before then but I wouldn’t have heard it because I was racing at the time.
The noise is in the drive train it has nothing to do with the engine, unbalanced tires, sticking brakes, pads, suspension etc…. As the noise only happens when in gear.

It sounds like a type of grinding noise its a hard one to describe.

The noise seems to only happen between 3500rpm – 2500rpm while decelerating only.

Noticeable the most in 4th gear, then 3rd, and then 2nd, you can hear it in 5th but it is the quietest of the gears.

I thought the sound was coming from the rear, so I checked the drive shaft universal joints and they are fine, next I pulled the diff head out and that also appears to be fine. The diff was rebuilt not long ago with new bearings, but with it out I did notice the axles were touching the LSD center so 4mm from each axle was machined off and when reinstalled the noise is still there, I would have thought 4mm from each side was enough to clear, I have also swapped the diff head over with a spare one and it still made the same sound so it isn't the diff.

I ended up pulling the gearbox out and replacing a few bearings











Some outside pictures

[zenki]

Wow , that enginebay is superclean .

[Ivan141]

hot hot hot....