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Old 06-03-2019, 13:39   #1
60ftLaunch
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Question Rear Diff Casing Material EVO 5 Vs EVO 8

Hello
I am replacing a broken rear diff on my evolution.
The actual casing cracked after hard shifting.
I know this is a common problem.

I would like to know if the later model EVO 8 differential is made from a stronger more shock resistant material that is less likely to crack (possibly a change in the alloy content) is this the case


I am not Looking to spend £1000 + on an EVO RS upgrade or to get a new Billet Centre housing machined

If the EVO 8 differential is indeed stronger would I be able to fit a CUSCO RS Limited slip differential that is currently in my Evo 5 after removing it ? or has the evo 8 diff Got a different internal Design ?

Last edited by 60ftLaunch; 06-03-2019 at 13:40..
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Old 06-03-2019, 15:20   #2
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Don't launch an Evo as they break

What engine torque are you running ?

The latter SAYC diffs are stronger due to a different internal design. Previous "upgrades" will not fit
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Old 07-03-2019, 13:42   #3
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Don't launch an Evo as they break



What engine torque are you running ?

The latter SAYC diffs are stronger due to a different internal design. Previous "upgrades" will not fit
thanks for the reply
I think I have around 341 ibft
so the Cusco type RS LSD will not fit in the Evo 8 Diff Casing btw I have my AYC disabled

Last edited by 60ftLaunch; 07-03-2019 at 13:47..
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Old 07-03-2019, 14:16   #4
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SAYC option kit looks like this

Name:  sayc rs diff.JPG
Views: 300
Size:  77.6 KB

Time to save up for a RS diff !
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Old 11-03-2019, 00:11   #5
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SAYC option kit looks like this

Attachment 323405

Time to save up for a RS diff !
Thanks for that

there are a few other options I am thinking about to reduce the shock on the drivetrain

but failing that I will fit an EVO RS DIFF
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Old 11-03-2019, 12:02   #6
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The Evo 5 has a weaker diff bearing support than the later ones where they beefed it up a bit and used a larger bearing. These are much stronger but also suffer from fatigue eventually. Look for a low mileage later model AYC unit
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Old 14-03-2019, 19:14   #7
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The Evo 5 has a weaker diff bearing support than the later ones where they beefed it up a bit and used a larger bearing. These are much stronger but also suffer from fatigue eventually. Look for a low mileage later model AYC unit
Thank for the information
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Old 27-03-2019, 10:39   #8
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The Evo 5 has a weaker diff bearing support than the later ones where they beefed it up a bit and used a larger bearing. These are much stronger but also suffer from fatigue eventually. Look for a low mileage later model AYC unit
Does the EVO 6 have the stronger bearing support that you mention or would I need an evo 7 Diff ?

BTW I just realised who you are and got to say the first time I saw your evo many years ago on the hillclimb I was amazing car

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Old 27-03-2019, 11:04   #9
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I think the 5 and 6 have the weaker casing and it was 7 onwards that was stronger

Thanks for your comment
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Old 03-04-2019, 21:56   #10
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I think the 5 and 6 have the weaker casing and it was 7 onwards that was stronger

Thanks for your comment
thanks alot for your input
I need to check if my Cusco LSD will fit in an evo 7 Diff casing ?
and will it be a direct swap or will I need to change the moustache bar and driveshafts /

hats off to you your car is amazing ,amazing to see the difference ground effect and aero makes and also the low boost threshold and instant throttle response from being twin charged .

reminded me of these Group B LANCIA's





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Old 04-04-2019, 10:00   #11
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I think the Cusco comes in 2 versions with the right bearing for each casing. The casing is thicker on the E7 onwards so the bearing is different. I honestly can't remember if the bearings can be swapped from one version to the other. Clive_W would be the best person to answer that

There's info here https://www.lancerregister.com/showt...f+strengthener on how to strengthen the casing but it means the AYC clutch packs have to be removed so the rear diff is essentially like an RS diff but in the AYC casing.

The external mountings and driveshafts should be the same between the E4/5/6 and the E7/8/9 AYC diffs.

There are a few other threads on MLR about the Cusco. There's useful information there if you have the time to go through them
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Old 04-04-2019, 11:05   #12
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I have a low mileage Evo 8 AYC diff complete and still in a car if you are looking for one.
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Old 04-04-2019, 19:45   #13
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Originally Posted by Madmac View Post
I think the Cusco comes in 2 versions with the right bearing for each casing. The casing is thicker on the E7 onwards so the bearing is different. I honestly can't remember if the bearings can be swapped from one version to the other. Clive_W would be the best person to answer that

There's info here https://www.lancerregister.com/showt...f+strengthener on how to strengthen the casing but it means the AYC clutch packs have to be removed so the rear diff is essentially like an RS diff but in the AYC casing.

The external mountings and driveshafts should be the same between the E4/5/6 and the E7/8/9 AYC diffs.

There are a few other threads on MLR about the Cusco. There's useful information there if you have the time to go through them
Great info thanks allot
thanks for the link aswell and will contact CLIVE THANKS AGAIN

Last edited by 60ftLaunch; 04-04-2019 at 19:54..
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Old 04-04-2019, 19:46   #14
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I have a low mileage Evo 8 AYC diff complete and still in a car if you are looking for one.
Hello I need to remove my old diff and check what type of CUSCO diff I have and if It will work with the EVO 8 Diff as another poster also mentioned it will not fit

will deffo contact you if I need it my friend
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Old 05-04-2019, 18:57   #15
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Cusco diff is different for E4/5/6 AYC and 7/8/9 AYC/SAYC

Also, and this is a big problem, the right hand bearing is now no longer supplied with the Cusco diff, and the standard Mitsubishi bearing doesn’t fit.
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