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  1. #1
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    Lightbulb VAC Motorsports - 335i, 135i Performance Built Differential - How we do it!

    Follow us on Facebook Click here to enlarge

    Hey guys,

    I am proud to say that we in fact do everything in house...nothing is outsourced.

    Well, this is a quick tutorial. As everyone knows, the ring gear is welded to the carrier. We wanted to do the best job possible, so we configured our CNC lathes and mills to handle this challenging task. The end result is beautiful =)

    VAC Performance Built Differentials are built to last with the highest quality components, procedures, and technical expertise in the industry. We have been building BMW differentials since the 1980s - 2002, E46, E92, street, race - we have done it.

    How is a VAC Performance Built Differential made (this is not a complete list, but most major operations are covered)

    1. Photograph and inspect every differential for damage/missing parts etc.

    2. Drain and inspect fluid looking for shavings or anything odd with the fluid.

    3. Remove cover, inspect ring gear, confirm gear ratio. Pictured: The infamous welded ring gear. Note how it is actually welded to the carrier.


    Click here to enlarge

    Click here to enlarge

    4. Test backlash before dissassembly.

    5. Remove axle shafts, old side cover seals, snap rings.

    6. Carefully remove the carrier.

    7. Remove inner races from carrier.

    8. Clean up the carrier, and prep for CNC operation.

    9. Set up the carrier in our ultra rigid and precise CNC lathe. Pictured: Stock welded ring gear/carrier on one of our lathes.

    Click here to enlarge

    10. Machine away weld that secures the ring gear to the carrier. This is an extremely robust weld.

    Click here to enlarge

    Click here to enlarge

    11. Remove the resultant step (weld) so it is flat enough to machine. Pictured: stock ring gear separated from carrier.

    Click here to enlarge

    12. Machine the ring gear flat (to ensure a precise mating surface for the new unit) Pictured: Separated ring gear | fully machined ring gear | drilled/tapped ring gear

    Click here to enlarge

    13. Set up the newly finished ring gear on our CNC mill. Pictured: Machined ring gear on our HAAS 5 axis machine.

    Click here to enlarge

    Click here to enlarge

    14. Machine the ring gear to make it compatible with the limited slip unit.

    Pictured: Completed ring gear still in the HAAS mill.

    Click here to enlarge

    Before:
    Click here to enlarge

    After: Note how we machine the entire face, not just the area where the LSD bolts. Our machining method ensures ideal accuracy and reliability. Not sure that anyone takes it this far.

    Click here to enlarge

    15. Assemble the limited slip unit.

    16. Pressure wash and paint the housing.

    17. Soda blast and clean the differential.

    18. Install bearings/snap rings.

    19. Check pattern, install seals, gasket material and differential cover. Pictured: Checking the pattern on the newly assembled differential.
    Click here to enlarge

    20. Tag and prepare for install/shipment. Pictured: VAC Performance Build Differential with optional Billet Differential Cover.

    Click here to enlarge
    Last edited by Mike@VAC; 02-14-2012 at 12:44 AM.

  2. #2
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    I am drooling! I will be ordering from you guys in the near future!
    From all the things I've lost,
    I miss my mind the most!
    Click here to enlarge

  3. #3
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    Great stuff Mike! Now get us some updates on the N54 cylinder head! you know i'll keep harassing both you and Chris until we get some numbers Click here to enlarge

  4. #4
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    I can vouch for these guys on this. I had them do my wavetrac, and as other people had all sorts of issues with install errors, I had it done right the first time, by these guys. Arguably one of the most abused diffs in a N54 equiped car, and as of selling the car (2yrs of use), not a single issue.

  5. #5
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    Looking forward to a thread like this but for an n54 cylinder head Click here to enlarge

    Great work you guys are doing there Mike!

  6. #6
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    Very Nice! Awesome pro work as usual by VAC. Thanks for posting up Mike.
    Click here to enlarge



    EURO 04 M3 Current Mods:GC DAs, Eibach Sways, PF RTAB's, RE RCAs, INTRAVEE II, Black Roundels, ///MFEST Badges, Depo's, Screen protector for NAV display, VCSL Bumper + Race Lip & CF Trunk & CF Rear Diffusor, DIETZ TV in Motion, SS= V1 Headers + catless pipes + X-Pipe + SS Sport Exhaust, Z8 Starter Button, Lamin-X, OEM CSL interior, OEM CSL Steering, OEM CSL Intake, OEM CSL Roof, MSS54HP + OEM CSL Tune, BBS CH's, LIGHTWERKZ, 355mm ST40 BBK, BW Oil Cooler....

  7. #7
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    Yes nicely detailed Vac!

    Hope we see something like this on the cylinder heads as well.

  8. #8
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    Very nice work, I'm thinking of doing this for my car. Is it really necessary on a street car like mine? I have no intention of tracking my car, will it make that big of a difference?
    Click here to enlarge
    ESS 6XX kit

  9. #9
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    Click here to enlarge Originally Posted by bobS Click here to enlarge
    Very nice work, I'm thinking of doing this for my car. Is it really necessary on a street car like mine? I have no intention of tracking my car, will it make that big of a difference?
    Well, an LSD is nice to have. You would notice it most when tracking, yes.

  10. #10
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    Click here to enlarge Originally Posted by Sticky Click here to enlarge
    Well, an LSD is nice to have. You would notice it most when tracking, yes.
    Ok thanks....it's on my "to do list", lol it never ends....
    Click here to enlarge
    ESS 6XX kit

  11. #11
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    Click here to enlarge Originally Posted by LostMarine Click here to enlarge
    I can vouch for these guys on this. I had them do my wavetrac, and as other people had all sorts of issues with install errors, I had it done right the first time, by these guys. Arguably one of the most abused diffs in a N54 equiped car, and as of selling the car (2yrs of use), not a single issue.
    Thanks bro. BTW - expect an email from me today ;0

    Click here to enlarge Originally Posted by 0-60Motorsports Click here to enlarge
    Very Nice! Awesome pro work as usual by VAC. Thanks for posting up Mike.
    Yea man! I saw the most recent exchange between you and Steve, just cc me on the replies to him.

    Click here to enlarge Originally Posted by dzenno Click here to enlarge
    Looking forward to a thread like this but for an n54 cylinder head Click here to enlargeGreat work you guys are doing there Mike!
    Click here to enlarge Originally Posted by Sticky Click here to enlarge
    Yes nicely detailed Vac! Hope we see something like this on the cylinder heads as well.
    Haha! I had a conversation with the team over some killer Lebanese food at lunch yesterday explaining how important it is to get this head on....we are building another diff for our 135i early next week, so the car will be mobile again. We want to do some baseline runs again on our Mustang and a nearby Dynojet before putting the head on.

    Click here to enlarge Originally Posted by bobS Click here to enlarge
    Very nice work, I'm thinking of doing this for my car. Is it really necessary on a street car like mine? I have no intention of tracking my car, will it make that big of a difference?
    Yes and yes. World of difference in my opinion on a modded 335i....talk to anyone who has made the switch and they will sell it better than I ever could. You can def feel it on the streets!! I have a smoking deal going on right now too. I will post a f/s thread on here today - its a cross forum GB of sorts

  12. #12
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    Thanks Mike Click here to enlarge
    Click here to enlarge



    EURO 04 M3 Current Mods:GC DAs, Eibach Sways, PF RTAB's, RE RCAs, INTRAVEE II, Black Roundels, ///MFEST Badges, Depo's, Screen protector for NAV display, VCSL Bumper + Race Lip & CF Trunk & CF Rear Diffusor, DIETZ TV in Motion, SS= V1 Headers + catless pipes + X-Pipe + SS Sport Exhaust, Z8 Starter Button, Lamin-X, OEM CSL interior, OEM CSL Steering, OEM CSL Intake, OEM CSL Roof, MSS54HP + OEM CSL Tune, BBS CH's, LIGHTWERKZ, 355mm ST40 BBK, BW Oil Cooler....

  13. #13
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    Beautifully machined.

    Click here to enlarge Originally Posted by Mike@VAC Click here to enlarge
    15. Assemble the limited slip unit.
    What unit do you use?
    Wavetrac, Quaife?

    The LSD cover looks drop dead gorgeous Btw.
    There are two theories to arguing with women. Neither one works

  14. #14
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    If I drive up to Philly how long would it take for you guys to finish the diff?
    Click here to enlarge

  15. #15
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    Click here to enlarge Originally Posted by DavidV Click here to enlarge
    Beautifully machined.
    What unit do you use?
    Wavetrac, Quaife?

    The LSD cover looks drop dead gorgeous Btw.
    Thanks! We sell Quaife, OS Giken and Wavetrac for the 335/135. Yes, the cover is amazing.

    Click here to enlarge Originally Posted by doogle Click here to enlarge
    If I drive up to Philly how long would it take for you guys to finish the diff?
    Budget 3 hours for a final drive swap. We have a nice showroom with wifi, tv etc. Click here to enlarge

  16. #16
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    Click here to enlarge Originally Posted by Mike@VAC Click here to enlarge
    Budget 3 hours for a final drive swap. We have a nice showroom with wifi, tv etc. Click here to enlarge
    Cool, will definitely have to head up to your shop once I get back to the states.
    Click here to enlarge

  17. #17
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    Click here to enlarge Originally Posted by Mike@VAC Click here to enlarge
    Yes and yes. World of difference in my opinion on a modded 335i....talk to anyone who has made the switch and they will sell it better than I ever could. You can def feel it on the streets!! I have a smoking deal going on right now too. I will post a f/s thread on here today - its a cross forum GB of sorts
    @bobS
    too lazy to rretype

    http://www.n54tech.com/forums/showthread.php?t=6795

    http://www.n54tech.com/forums/showpo...0&postcount=12

  18. #18
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    Ok ok, you and mike have talked me into it, I'm going to go look for that group buy!
    Click here to enlarge
    ESS 6XX kit

  19. #19
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    Click here to enlarge Originally Posted by Mike@VAC Click here to enlarge
    Thanks bro. BTW - expect an email from me today ;0

    ok, will do!

  20. #20
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    1 out of 1 members liked this post. Reputation: Yes | No
    Thanks for the PMs, emails, calls guys!

    Core ring gears about to be separated!

    Click here to enlarge

  21. #21
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    535 application too?
    08 535i 6MT - JB4 G5 ISO - Luke performance flash - E40 & BMS 100% Meth - AR design catless DP - ETS 5" intercooler - BMS DCI - BMS OCC - ER chargepipe - HKS BOV - K-sport coilovers - UUC evo SSK - CDV deleted - ACS spoiler - Click here to enlarge

  22. #22
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    Click here to enlarge Originally Posted by hkninja Click here to enlarge
    535 application too?
    @Mike@VAC

  23. #23
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    VAC are great and Mike was excellent to work with!
    From all the things I've lost,
    I miss my mind the most!
    Click here to enlarge

  24. #24
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    Any prices? This looks very nice.

    +1 on the cylinder head.

  25. #25
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    My vac LSD is awesome, highly recommended mod for the 335
    Click here to enlarge
    ESS 6XX kit

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