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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > N54 Turbo Engine / Drivetrain / Exhaust Modifications - 335i > Billet front diff housing with stronger gears



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      07-11-2016, 07:50 AM   #1
reaper0995
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Billet front diff housing with stronger gears

I'm researching to build a billet housing that will hold a stronger ring and pinion for the front diff. Space is pretty tight, but it looks feasible. Hoping to make a diff that could handle a 1000awhp car, with approx 30-40% going to the front. Most likely have a custom front driveshaft too.

My question to everyone here is what would people want in it for options? I was building the design around 3.08 gears for manuals, but also have 3.46 gears available for autos. Any other gear sizes that would be wanted? What about cooling, just some fins for air cooling, or would water passages to allow for coolant to flow through be ideal? Goal is to have as much diff fluid as possible, hoping a liter+.


Thoughts? Who is interested in something like this? And what would be N acceptable price target?


Just as a background for me, I'm a manufacturing engineer at a fairly largue company. Worked on performance cars for years, everything from total custom weird race cars, diff regearing, engine builds, turbo fabrication, etc. even built the turbo setup for my hayabusa but that was over tn years ago and my welding skills weren't great at the time lol.

Last edited by reaper0995; 07-11-2016 at 09:46 AM..
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      07-11-2016, 08:09 AM   #2
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I have no clue what any of this means. All i know is our front diffs are some shit. So im in to buy when its ready.
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      07-11-2016, 09:58 AM   #3
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Went through 2 diffs. I would also buy if the price is right
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      07-11-2016, 01:43 PM   #4
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Maybe I'm missing something, but how will you determine torque split using only an upgraded front diff? Are you planning transfer case work too?
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      07-11-2016, 02:08 PM   #5
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I would be interested too. The T-Case doesn't seem to be a limiting factor at this time
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      07-11-2016, 02:32 PM   #6
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Quote:
Originally Posted by Yournamehere90 View Post
Maybe I'm missing something, but how will you determine torque split using only an upgraded front diff? Are you planning transfer case work too?
No plans on the transfer case itself, but I might try and play with the controller, actuator, override it entirely, or hope that another person solves that riddle! Not really sure what to do yet, but my first guess is to just unplug the unit and make a completely contained controller that has a toggle switch between 0/100, 20/80, 40/60, etc.
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      07-11-2016, 06:13 PM   #7
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Here are some photos of the initial size I have to work with. It's tight,but it looks like I might be able to get some 7.2 inch diameter gears in there. The stock ones are just over 6 inches in diameter.

Have people had the spider gear carrier break? It would be ideal to not have to replace that, or at the least not have to make new spider gears... most likely replace gears first then go down the line of needed.
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      07-11-2016, 07:16 PM   #8
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I'm not familiar with the BMW awd system other than it doesn't like hard launches. What usually breaks? The ring gear, pinion gear, shafts, or carrier or what?
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      07-11-2016, 09:29 PM   #9
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Quote:
Originally Posted by Yournamehere90 View Post
I'm not familiar with the BMW awd system other than it doesn't like hard launches. What usually breaks? The ring gear, pinion gear, shafts, or carrier or what?
I'm not entirely sure, but it doesn't sound like anybody has a solid idea... I think the replacements are cheaper than trying to rebuild, hence why there isn't any real info on what fails.

Looking at the unit I have, I'd guess that the bearings are not trapping the ring and pinion good enough and under high loads, or sudden hard launches, they get mis aligned and cause failure. Just a guess though. Also the one side is actually spring loaded! Albeit a pretty heavy duty spring washer, but thought that was interesting to float ball bearings for the diff alignment.
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      07-12-2016, 01:41 AM   #10
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I would definitely be interested in this, it is by far the limiting factor in these cars right now
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      07-12-2016, 03:02 AM   #11
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The BMW front diffs are actually pretty stout. Just because a few people with almost double the power over stock, have shock broken them (wheel hop and abuse), doesn't mean they are shit. They are actually stronger and better designed than a GM 10-bolt from a RWD V8.

I'm in the 11's at the drag strip, and my 97K mile front diff will be fine.
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      07-12-2016, 07:07 AM   #12
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Quote:
Originally Posted by Cory S View Post
The BMW front diffs are actually pretty stout. Just because a few people with almost double the power over stock, have shock broken them (wheel hop and abuse), doesn't mean they are shit. They are actually stronger and better designed than a GM 10-bolt from a RWD V8.

I'm in the 11's at the drag strip, and my 97K mile front diff will be fine.
I don't think they're necessarily horrible, but I just don't see them holding up to 1000awhp and getting deep into the 9's. Also worth noting the 7.2 gears in thinking about using are not the GM 10 bolt. It's actually from the SyTy front diff, and was going to get aftermarket upgraded stronger gears... Yukon perhaps? It looks like it also has a favorable hypoid offset as well.
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      07-12-2016, 10:33 AM   #13
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Here's pics of my front diff that messed up. It Happened to me twice smh.
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      07-12-2016, 10:36 AM   #14
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Quote:
Originally Posted by Julian2485
Here's pics of my front diff that messed up. It Happened to me twice smh.
Pics of front differential
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      07-14-2016, 09:42 AM   #15
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I cant wait. Im so sick of being scared to push mycar
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      07-14-2016, 11:16 AM   #16
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Quote:
Originally Posted by reaper0995
Quote:
Originally Posted by Cory S View Post
The BMW front diffs are actually pretty stout. Just because a few people with almost double the power over stock, have shock broken them (wheel hop and abuse), doesn't mean they are shit. They are actually stronger and better designed than a GM 10-bolt from a RWD V8.

I'm in the 11's at the drag strip, and my 97K mile front diff will be fine.
I don't think they're necessarily horrible, but I just don't see them holding up to 1000awhp and getting deep into the 9's. Also worth noting the 7.2 gears in thinking about using are not the GM 10 bolt. It's actually from the SyTy front diff, and was going to get aftermarket upgraded stronger gears... Yukon perhaps? It looks like it also has a favorable hypoid offset as well.
So is this a definite that you will be making upgrade front diffs ?
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      07-14-2016, 02:17 PM   #17
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Quote:
Originally Posted by Julian2485 View Post
So is this a definite that you will be making upgrade front diffs ?
Yeah just a matter of time and money at this point! I need a few more parts, but I'm already reverse engineering the housing and carrier. This won't be a fast process, but it is just a side hobby thing for me. I'm only wanting to build this to put in my car, and hopefully make enough money from selling these to pay for my future upgrades

I don't know how much this is going to cost yet, but it's looking like it will easily be over $1500, probably closer in the $2-3k range... But I'm trying to see what I can do to keep costs reasonable and have a solid product. Thankfully I know a lot about manufacturing and keeping costs low! As a point of reference though, the R35 GTR's have a billet housing for the front diff that is $3400, housing ONLY with no internals!!! I want to make a complete unit for sale, and be less than that...
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      07-14-2016, 02:34 PM   #18
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I can be a tester! Have a lift and everything to do install
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      08-27-2016, 06:48 PM   #19
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      08-27-2016, 08:12 PM   #20
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Any progress
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      08-27-2016, 08:31 PM   #21
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Quote:
Originally Posted by Julian2485 View Post
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      08-28-2016, 01:31 PM   #22
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Quote:
Originally Posted by Cory S View Post
The BMW front diffs are actually pretty stout. Just because a few people with almost double the power over stock, have shock broken them (wheel hop and abuse), doesn't mean they are shit. They are actually stronger and better designed than a GM 10-bolt from a RWD V8.

I'm in the 11's at the drag strip, and my 97K mile front diff will be fine.
Generally, I admire the content of your posts - but, I think this may be a tad optimistic.

Do you have any data to support this position?
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