The resurrection of my sr s13 build thread.

General discussion forum about the 240sx, and a great place to introduce yourself to the board!
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kornmanz
Posts: 2926
Joined: Wed Sep 26, 2007 5:01 am
Car: 89 240sx Hatch SR Powa'd
Location: Santa Fe, NM
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So my car has been sitting for over a year now. It's a pretty sad thing when you can only look at your 240 and not drive it. Well I recently got some money from my school grants and figured its time to breath some life back into my baby.

This is what the engine bay used to look like:

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This is how it looks after a year of sitting:

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This is an old body shot of the car:

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This is how it sits now. On some jack stands ready to be worked on.

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So I ordered a brand new kaaz 2 way diff, 1 piece steel driveshaft, and a new starter since those were the 3 things I knew needed to be replaced to drive her again.

The driveshaft is still on its way in the mail. I got the diff today though.
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So then I ripped out the old diff and driveshaft:
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Hello old diff:

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Say goodbye to your outside gear:

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A nice set of tools really makes the job easy.
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And yes that is a silenced m4 being cleaned sitting on top of the toolbox.
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Cleaning the inside of the pumpkin.
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Aww don't they look cute together? They're all one big happy family!
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When cleaning the diff pumpkin and removing the old gasket which tool would you prefer? The old school scraper? Nah...f that.
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The angle grinder made quick work of that old gasket.
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Next was putting the main gear on the new diff.
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Make sure to scrub that sucker clean with a wire brush and some good cleaner.
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Hello cleaned half shafts.
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These are the bolts that bolt the main gear onto the diff. A good cleaning is recommended so they sit and seal right.
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Time for the fun part.
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Blam got those on.
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Oooooh lookin sexy:
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When I took out the old diff I did not pay attention to where the washer type things went. It seems I got them wrong thank you Hijacker for informing me. I will go fix that tomorrow.

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Quick bolt up.
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Half shafts on.
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Bolted up the cover and filled it with standard gear oil for the break in when that comes. The diff is sitting waiting to be put back into the car but I'll do that when the driveshaft comes in next week. For now I'm gonna start unbolting the intake mani so I can check all my tubing n whatnot. I remember coolant kept leaking from this area so I'll need to investigate.

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More updates to come as progress is made!
Last edited by kornmanz on Tue Nov 09, 2010 4:52 pm, edited 2 times in total.


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Hijacker
Posts: 14373
Joined: Wed Aug 13, 2003 4:57 am
Car: '92 240sx Convertible
'94 F-150
Location: Fredericksburg, VA

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Oh my. you are very mistaken about how you put your diff back together. Those smaller ones are shims. They should technically be one on each side. The fat washer should be on the left side of the pumpkin (the side away from the ring gear). Then you have to do some math and testing to figure out which shim thickness you need to space the diff properly inside while giving it the proper pre-load. With the way you have it set up, your backlash will be off, and the thing is gonna rattle. Worst case, it'll strip teeth off the ring gear.

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kornmanz
Posts: 2926
Joined: Wed Sep 26, 2007 5:01 am
Car: 89 240sx Hatch SR Powa'd
Location: Santa Fe, NM
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Oh s*** thank for the correct way. I couldn't find the write up I was referencing that had detailed pics so I guessed the fat piece should push the gear against the bottom gear.

I will fix the spacers. Other than that I will not be able to do any other adjustments.

I will not trust my car in the hands of local shops. They f'd the s*** out of my exhaust install and it was just an exhaust install. Plus they like to really rape you for money. They charged me 280 dollars to mount up my exhaust and they royally messed it up which I found out months later.

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kornmanz
Posts: 2926
Joined: Wed Sep 26, 2007 5:01 am
Car: 89 240sx Hatch SR Powa'd
Location: Santa Fe, NM
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Btw hijacker you were wrong. The fat washer still goes on the right side. If it is on the left side the ring gear will not touch the gear in the back of the pumpkin. One small one on each side and fat washer on the right side (side of ring gear) is how it goes for my diff.

Updates:

Today I decided to fix the washer problem, clean the pumpkin, coat it with anti rust and mount it up.

Cleaned up:
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Mounting it:
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This thing made it almost too easy to get those bolts back on.
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Then was attaching the half shafts back to the axles. Easiest way I found was using this type of wrench:
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That light in the background is perfect for low visibility situations.

I positioned the wrenches like so. Using the longer one to wedge against the frame for the most leverage. Was pretty simple.
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Still waiting on my driveshaft. I think I'll get the starter installed next as well as I may be ordering a rear sway bar.

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breadbox
Posts: 8549
Joined: Tue Oct 17, 2006 4:09 pm
Car: 89 Nissan 240SX
89 Koop
84 720 4x4KC
Location: Va Bch

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Very nice ZZ. I want a Kaaz, let me know how fun it is.

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kornmanz
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Joined: Wed Sep 26, 2007 5:01 am
Car: 89 240sx Hatch SR Powa'd
Location: Santa Fe, NM
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I was going to just replace it with a stock one at first but then it dawned on me to just go out and get the kaaz. I'm excited to see how responsive the car will be after the driveshaft and diff are in. :)

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badbob2121
Posts: 1989
Joined: Sat Jan 16, 2010 9:23 am
Car: '92 Nissan 240SXS13 Hatch ELLIS JUAN
'12 Ford Mustang GT RTR
Location: St. Louis

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pretty sweet, who needs a free good education when u can fix your s13? :slap:

looks good though

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kornmanz
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Joined: Wed Sep 26, 2007 5:01 am
Car: 89 240sx Hatch SR Powa'd
Location: Santa Fe, NM
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Lol well when i get money just to attend classes and after paying for books and tuition and still have money left over. I gotta fix my baby.

:)

Driveshaft comes in friday!

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kornmanz
Posts: 2926
Joined: Wed Sep 26, 2007 5:01 am
Car: 89 240sx Hatch SR Powa'd
Location: Santa Fe, NM
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So today I went to install the new starter and to take a look at what was causing the engine to leak coolant from underneath the intake manifold.

First things first was to take off the hood. The hood was blocking the dome light of the garage and made the engine bay very dark. Simple as removing these bolts.

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Cool now the hood is gone. I can see.
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Goodbye manifold.

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Now this is where some confusion came. I found what was leaking. It was a busted rubber plug that went on this nipple. This is not meant to be plugged up right? I made a new thread about it because I want to know if something is wrong here.

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New starter vs old starter
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New starter in
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taking apart manifold and throttle body to clean

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cleaned

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Now another confusing thing is why am I missing bolts on my transmission?

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Lots of fun finds today.

Driveshaft comes in tomorrow.

TheBlaiant
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Car: Slow40sx
Location: Miami, FL
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Those bottom bolts on trannys are always missing lol. They go to some braket that hooks up to the block.

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kornmanz
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Car: 89 240sx Hatch SR Powa'd
Location: Santa Fe, NM
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Oh ok good lol. I looked at it like "ummmm...."

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kornmanz
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Joined: Wed Sep 26, 2007 5:01 am
Car: 89 240sx Hatch SR Powa'd
Location: Santa Fe, NM
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So today was starting her up for the first time in about 2 years as well as getting the exhaust and driveshaft bolted up.

I let them bond over night.

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Then they were joined together in matrimony.

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Then I started her up:



I noticed my cluster gauges were not working so I took the dash apart to find that the previous owner did a terrible wiring job.

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This is gonna be fun trying to get the gauges working again.

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240life
Posts: 1313
Joined: Mon Sep 24, 2007 6:02 am
Car: 1993 Nissan 240SX S13 Coupe SR20DET blacktop
Location: ME
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Looks good, Im about to mate my sr with a 240 for the first time in a year, and I got the same issue, no cluster lol. I too will be removing my dash to take a look at the previous owners wiring. Hopefully you get your figured out :crazy:

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kornmanz
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Joined: Wed Sep 26, 2007 5:01 am
Car: 89 240sx Hatch SR Powa'd
Location: Santa Fe, NM
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Yeah I'll def post about it if I figure it out. Will probably have to take the whole dash off to figure out the problem. Before that though I'm gonna check all the wiring in the engine bay probably tomorrow.

Post up a thread when you put that SR in. Sr's are serious fun.

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kornmanz
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Joined: Wed Sep 26, 2007 5:01 am
Car: 89 240sx Hatch SR Powa'd
Location: Santa Fe, NM
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For anyone whose interested the mod list is as follows:

Greddy titanium valve springs
crower titanium valve set
crower 272 cam set
phase 2 motorsports rocker arm stoppers
pro-machine acid treated head
pro-machine multi angle valve job
pro-machine ported and polished ports
ARP head bolts and studs
HKS 1.04mm multilayer metal head gasket
brian crower bronze valve guides
OEM valve seals (new)
OEM timing chain tension-er (new)
5 Ziegen Oil cap

Nismo rod bearings
NIsmo main bearings
Nismo thrust bearings
Eagle h-beam rods
OEM pistons (new)
OEM rings (new)
OEM oil pan (new. Got replaced because other one was dented)
Greddy blow-by canister
ARP rod bolts
Greddy aluminum pulley set

Aeromotive tsunami fuel pump
aeromotive 100 micron inline fuel filter
aeromotive fuel pressure regulator
aeromitve fuel pressure gauge
greddy fuel pressure fittings
BGRG custom high pressure fuel lines with 6AN fittings
Apexi SAFC 2 fuel controller
Z32 Mass air flow sensor
Mishimoto Starter

Samco braided radiator hoses
greddy radiator cap
koyo polished aluminum radiator
12" electric fan
Phase 2 motorsports aluminum coolant tank
B-road carbon fiber air diversion plate
AEM air filter

Stock turbine
Greddy turbo timer
BGRG steel braided oil return line
HKS equal length exhuast manifold
JDM lab aluminum intercooler
JDM lab intercooler piping
Blitz BOV
Apexi Downpipe
Apexi dual N1 Exhaust system

Z32TT dual piston front calipers
Z32TT brembo rotors
240sx rotors (rear)
phase 2 motorpsorts steel braided brake lines
tokiko shocks
tein s springs
FR and RR began racing strut tower braces
Kaaz 2 way differential
Driveshaft Shop 1pc Steel Driveshaft

Also the first build thread I made on here is located here:

kornmanz-s-build-finally-t372388-40.html
Last edited by kornmanz on Tue Nov 09, 2010 5:45 pm, edited 2 times in total.

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240life
Posts: 1313
Joined: Mon Sep 24, 2007 6:02 am
Car: 1993 Nissan 240SX S13 Coupe SR20DET blacktop
Location: ME
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kornmanz wrote:Yeah I'll def post about it if I figure it out. Will probably have to take the whole dash off to figure out the problem. Before that though I'm gonna check all the wiring in the engine bay probably tomorrow.

Post up a thread when you put that SR in. Sr's are serious fun.
a-new-beginning-t476771.html there it is if you want to check it out

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kornmanz
Posts: 2926
Joined: Wed Sep 26, 2007 5:01 am
Car: 89 240sx Hatch SR Powa'd
Location: Santa Fe, NM
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Oh yeah I actually read your thread man. Looks good. You're pulling apart everything haha. That KAT aint lookin so bad either. I want those new wheels you got btw. yummmm!


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