Most AE86 had the small S-series 162mm diff

Why would you want to 4.9 diff? For the 2.62:1 gear ratios?

Looks like it is a T-series 170mm diff, Prior to 1985 (S-series 162mm didn't have available LSDs). Corona, Corolla, etc. Might be easy to find in the wreckers.

The newer T-series from 1985 uses larger diameter axles.

That $349 LSD says it is for the 1986-1987 version. The TRD LSD was $850 but looks like they discontinue.

There is a Tomei LSD for $712

Getting very interesting if only some ex-Hitachi engineer would help us out from a Japanese site maybe B-projects Japan would know this info?

That conversion you posted DD is a late centre or early centre taking smaller axles?

Not sure. I can't read it very well. Link is in first post.

I'm guessing it is early T, which uses 24mm axles. What are the H165 ute axles?

Here are the Pitroad pages:
http://www.pitroad-ts.com/A-parts-2/h165trd.htm
http://www.pitroad-ts.com/process-2/ae86lsd.htm

Which lsd did you use? Zenki (83-85) or kouki (86 onwards)? Zenki is a couple mm smaller in diameter so i wanna make sure i get right size before i give this a go.

This is from parts sellers on Yahoo Japan.

From what I can tell, it is T-series. Zenki and Kouki are same diameter ring & pinion (CRP), but the axles are different size.

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I have fitted an AE86 6.7" TRD 2way LSD centre into an H165 diffhead.

-I had the centre machined to allow the H165 crownwheel to fit over it.

-Sleeves were made to fit inside the LSD centre crownwheel bolt holes to accommodate the space left from the narrower OD H165 crownwheel bolts.

-Brand new bearings for the AE86 centre were used, with the cup OD machined down (on an expensive specialist machine) to fit in the H165 bearing housings.

-The LSD centre was machined inwards on the side bearing journals to allow for shims to be added to adjust side bearing preload and align teeth mesh pattern (shims were fitted between centre and bearing cone, advised by diff specialist next time to have shims fitted on outside between diff housing and bearing cup).

-Diff assembly was assembled with new pinion bearings and seal, and adjusted to specs (diff specialist fitted a solid pinion spacer as diffhead to be used in an S110 Silvia disk brake rear end in an early 79 Sunny B310 with CA18DET and his concern was the extra torque the diff would need to handle

*** All machining was very minimal and done professionally. As there was concern over removing material and creating weaknesses we looked into the safest and most functional way to achieve the strongest most reliable result worth the effort***

I have another diff to finish and assemble, I could look into some pictures and a technical thread if people would like?

thats whats been missing for the h165 fans, great stuff and thanks for the heads up
would be great to see the process of it all, sounds very complicated

The LSD they use in Japan is the AE86 6.38" unit (S-series?). The AE86 6.8" unit (170mm) requires the mods

The earlier AE86 LSD supposedly only needs the bolt sleeves (for pre-1986, 1986-up H165 already uses the bigger bolts)