So.. i found the source of the noise.. doesn't look good

[MC2]

I've been talking about this chatter that i have coming from the rear passenger side. Today I was sawpping the diff with a new (used) one.. once i had it off of the front diff member i noticed this:

Passenger side bracket is pushed up into the bushing and front member
http://dl.getdropbox.com/u/32331/Diff%20member%20bushings/IMG_0696.jpg

http://dl.getdropbox.com/u/32331/Diff%20member%20bushings/IMG_0699.jpg

pushed right up against the stopper on top
http://dl.getdropbox.com/u/32331/Diff%20member%20bushings/IMG_0701.jpg


This is the drivers side. You can see the even spacing between the bracket, member/bushing, and the stopper on top
http://dl.getdropbox.com/u/32331/Diff%20member%20bushings/IMG_0707.jpg

http://dl.getdropbox.com/u/32331/Diff%20member%20bushings/IMG_0704.jpg

Looks like the previous owner ran into something pretty hard... What do you think has happened here and what do i need to replace? To me it almost looks as if that entire bolt got pushed right up into the car.. that would mean the threads inside there are hosed and the bolt is probably stripped in there pretty bad. What do you guys think?

[chuckthefuk]

That lower bracket is a flimsy piece of metal you can bend it back into whatever shape you wish. You can replace the diff outrigger bushings with stock or upgraded. Noltec sells the entire assembly with cradle and kartboy/tic sells just the upgraded spacers.

I doubt that the "T" brace that supports the diff to the outriggers is bent/damaged.

Now if the bolt is rusted and the threads seized you can try this. I ran into a similar problem when swapping a gas tank on 95 impreza. The only option at the time was to replace the bolt with a new one and drill a hole from the top (floor) to get a socket on the nut. Not the best solution but it worked.

-Chuck