Cone Type Locking

Fig. 4 Cone type (Borg Warner) locking differential exploded view:

Fig. 5 Differential case bolt torque sequence. Borg Warner locking differential:

1. If removing ring gear, clamp case in a vise so jaws are 90° to pinion shaft holes and remove ten ring gear retaining bolts.
2. Partially install two bolts on opposite sides of ring gear.
3. Remove ring gear from case by alternately tapping on bolts. Do not pry between case and ring gear.
4. Remove differential case half attaching bolts, Fig. 4.
5. Lift cap half of case from flange half. Remove clutch cone/side gears, spring blocks, preload springs, pinion gears and shaft. Mark each clutch cone/side gear and pinion gear so they can be reinstalled in their original position.
6. Clean and inspect all parts and replace as necessary. Slight grooves or scratches, indicating passage of foreign material, are permissible and normal. If case or clutch cone/side gear are damaged, it is necessary to replace case assembly. All others parts are serviceable.
7. Install proper cone/gear assembly into position in cap half of case.
8. Place one spring block in position over gear face, in alignment with pinion gear shaft grooves. Install pinion shaft, pinion gears and thrust washers into cap half or differential case in such a manner that pinion shaft retaining dowel can be inserted through pinion gear shaft into differential case. Be certain that pinon gears are installed in their original location.
9. Insert five springs into spring block that is already installed in case, then place second spring block over springs.
10. Install second cone/gear assembly face down on spring block so that gear will mesh with pinion gears.
11. Install flange half of differential case over cone, insert case bolts finger tight. Tighten bolts one turn at a time in sequence shown in Fig. 5. Then torque case bolts to 30 ft. lbs.
12. If ring gear was removed, position it so that holes line up with case holes.
13. Lubricate NEW attaching bolts with clean engine oil and install.
14. Tighten bolts evenly and alternately around the case. When all bolts are snug, torque evenly and alternately to 120 ft. lbs.