There are some interesting things to note here. Out on the road, we do see spider gear failures at least as often as casing failures. We didn't see any spider gear failures in our testing. We also were not able to shear the driveshaft bolts, which seems to happen often in real life. I suspect the reason for this is that these failures are either related to the shock of a launch/hard shift, or they are due to fatigue over time. Our test is quasi-static, meaning we applied the force in a slow and controlled manner. This does not provide a shock to the system that may be needed to break the spider gears inside the diff. Shock also has a large effect on shearing bolts, though improper torque and reusing bolts can also affect their strength. Our gut feel is that the driveshaft bolt failures are more likely attributed to improper installation and/or too many uses.
Regardless, we were able to recreate the casing failure the differential brace aims to address and can say definitively we were able to prevent it!
- Differential brace
- Center section
- Left upright
- Right upright
- 2 rear differential bushing inserts (required to mount brace)
- Forward lower differential bushing insert (required to mount brace)
- All required hardware including new longer bolts to attach differential to subframe
- Audi B8/8.5 A4/S4/RS4 and A5/S5/RS5 with Sport Differential (DBR02A0)
- Audi C7 A6/S6/RS6 and A7/S7/RS7 with Sport Differential (DBR01A0)
- Audi D4 A8/S8 with Sport Differential (DBR01A0)
Full Assembly
DBR01A0 - for C7/D4
DBR02A0 - for B8