Limited Slip Differential
Fig. 12 Limited slip differential exploded view.:
Fig. 13 Limited slip differential exploded view.:
DISASSEMBLY
1. Remove ring gear and case side bearings, if necessary, as outlined for standard differential.
2. Evenly loosen bolts securing case cover, then remove cover.
3. Invert case over work surface and allow component stack, Figs. 12 and 13, to slide from case, tapping case with mallet to aid removal. Keep all components in order to ensure proper assembly. Components that are to be reused should be installed in original position to ensure proper operation.
4. Clean components with suitable solvent and blow dry with compressed air.
5. Inspect components and replace any that are damaged, distorted or excessively worn, noting the following:
a. Replace inner and outer plates if coating, splines or tabs are worn, or if they fail to operate properly.
b. Check fit of thrust rings in case and replace as needed if rings bind or stick, or if excessive play is evident.
c. Replace side gears and pinion assemblies if teeth are damaged or excessively worn, or if side gear splines are worn.
SIDE GEAR CLEARANCE ADJUSTMENT
1. Install pressure rings, side gears and differential pinion gear and shaft assembly in case, Figs. 12 and 13, ensuring that components are properly seated.
Fig. 14 Measuring case assembly depth for side gear clearance. Models w/limited slip differential:
2. Measure dimension ``A'', Fig. 14, from case cover mounting flange to outer face of side gear and record measurement.
Fig. 15 Measuring case center & flange depth for side gear clearance. Models w/limited slip differential:
3. Measure dimension ``B'', Fig. 15, from raised portion of case to center depression and dimension ``C'', Fig. 15, from raised portion of case to mounting flange. Subtract dimension ``C'' from dimension ``B'' and record remainder.
4. Add remainder obtained in step 3 to dimension ``A'' obtained in step 2 to obtain total side gear clearance.
5. Select a combination of thrust washers, diaphragm springs and stepped washers, if equipped, for each side having a total thickness of one half of the total side gear clearance minus .004 inch.
CLUTCH ASSEMBLY CLEARANCE ADJUSTMENT
1. Install spacer (500, 600 and 700 series only), outer plate, inner plate, thrust ring and side gear in differential case, ensuring that side gear is properly seated. Thrust washers, stepped washers, and diaphragm springs, as equipped, are not installed until assembly clearances have been measured.
2. Install differential pinion assembly, ensuring that pinion shafts are located in thrust ring notches.
3. Install remaining side gear with hub facing up, then the thrust ring, inner plate and outer plate.
Fig. 16 Measuring case assembly depth for clutch pack clearance. Models w/limited slip differential:
4. Ensure that components are properly seated, then measure distance ``A'' from case cover mounting surface to top of outer plate, Fig. 16, and record measurement.
Fig. 17 Measuring case cover flange depth for clutch pack clearance. Models w/limited slip differential:
5. Measure dimension ``B'' from raised portion of case cover to cover mounting surface, Fig. 17, and record measurement.
6. Measure combined thickness ``C'' of diaphragm springs, and record measurement.
7. An assembly clearance of .004 to .016 inch is necessary to prevent total compression of clutch pack diaphragm springs. Obtain total assembly clearance as follows:
a. Add recorded case cover height ``B'' to total diaphragm thickness ``C'', and record sum.
b. Subtract sum obtained in previous step from assembly height ``A'' to obtain clutch assembly clearance.
c. If remainder obtained in previous step is not .004 to .016 inch, replace outer plates as needed to obtain specified clearance.
d. If assembly clearance is less than specified, select and install thinner outer plates. If assembly clearance is greater than specified, install thicker outer plates. Select plates to obtain clearance as close to .004 inch as possible.
e. Install selected outer plates as outlined and ensure that assembly clearance is within specifications.
8. Remove selected components from case, keeping components in order for final assembly.
Fig. 13 Limited slip differential exploded view.:
500, 600 & 700 Series
1. Install side gear trust washer (2) with oil grooves facing down and diaphragm spring (3), Fig. 13, with concave side facing up.
2. Install stepped washer with smooth side toward diaphragm spring and tab engaged in case notch.
3. Install spacer and clutch pack diaphragm spring (5), with concave side of spring facing up.
4. Install outer plate, inner plate and thrust ring, ensuring that guide tabs are properly engaged.
5. Install side gear, turning gear to engage inner plate splines or guides.
6. Install differential pinion and shaft assembly, and the remaining side gear and pressure ring, ensuring that components are properly seated.
7. Install inner plate, outer plate and clutch pack diaphragm spring (5), Fig. 13, with concave side of spring facing down.
8. Install side gear thrust washer (2) and diaphragm spring (3) in case cover, with thrust washer oil grooves facing cover and concave side of spring facing inside of case.
9. Install stepped washer in cover with smooth side toward diaphragm spring and tab engaged in cover notch. Use grease to retain thrust washers and spring in cover during assembly.
10. Temporarily install cover assembly, ensuring that thrust washers and springs remain in place, and evenly torque bolts to 22-24 ft.lbs.
11. Install drive flanges, then mount assembly in suitable fixture with one drive flange blocked to prevent rotation.
12. Fabricate suitable tool to allow remaining drive flange to be rotated with torque wrench, then check assembly slip torque by rotating one flange while the other flange is blocked.
13. Slip torque should be 36-54 ft.lbs. for 500 and 600 series models or 80-94 ft.lbs. for 700 series models. Slip torque is controlled by the thickness of the outer clutch plates. If slip torque is less than specified, install thicker outer plates; if torque exceeds specifications, install thinner outer plates. When replacing clutch plates to adjust slip torque, ensure that clutch assembly clearance is maintained within the specified .004 to .016 inch.
14. After slip torque is properly established, install case cover as previously outlined using suitable thread locking compound on retaining bolts, then evenly torque bolts to 22-24 ft.lbs. in crossing pattern.