Team Associated Diff kit rebuild

In this write up I will be providing walk through step-by-step instructions on how to assemble or rebuild your Team Associated diff.  Below is the actual kit and also the rebuild kit.

 In my write up I will be will be rebuilding a diff but the assembly of a fresh new diff is the same. 

You will need the following items.  The electric motor spray is only needed to clean parts if you plan on rebuilding a used diff.  The two types of greases will be needed to build the diff.

First, remove the diff from the car and disassemble the kit using an Allen wrench from one side of the diff.

Clean all used parts with the motor spray.  After spraying the parts be sure to wipe clean with paper towel.  I found it easier to spray the towel first before cleaning the balls.  Roll the balls with your finger on the wet paper towel.  Careful, they are easy to lose.  There are two different sizes so beware not to mix them up.

Now it’s time to assemble the diff.

Apply a small bead of clear grease to inside of both outdrives as show below.

After you have applied the grease install one steel plate on each end.  Note: Be sure to line up notch correctly on each plate as shown.

Next, install a small amount of clear grease in each hole of the main gear and install one ball in each hole.  Tip: It makes the job easier to add small amount of grease to the end of a toothpick to pick up each ball and input into hole.

 Then add small amount of clear grease to top and bottom of gear.

Set main gear on shorter outdrive and shown below.  The applied clear grease should stick the gear to the outdrive.  Once you confirm you have the gear on the correct drive place the longer outdrive on top as shown.

The last part of the assembly is to assembler the thrust balls.  There are 7 of these.  Be sure to use the black grease at this time.

Assemble the screw as in the picture below.

Using a bench vise or other tools may help in this next step.  Apply small amount of black grease all the way around top washer as shown.

Using a toothpick again place each of the seven thrust balls around the washer as shown. Once all seven balls have been set correctly place the last small washer on top.

Last step is using the Allen wrench, carefully insert assembled screw into long end of outdrive as shown.

Use something flat to hold other end while you tighten down the diff.  Once the screw is tight stop tightening and back out about a half of a turn.  DO NOT OVER TIGHTEN.

 Use the illustration below to guide how tight to have your diff.