Locking Differential Adjustment

1. Assemble the clutch plates. Alternate the plates as shown.
2. Assemble the guide clips and to the plates. Use grease in order to hold the clips in place on the plates.
3. Install the side gear thrust washer, the clutch plate assembly and the right side gear to the differential.
4. Place the pinion gears and the thrust washers into the differential.
5. Align the gears and the washers with the pinion shaft hole.
6. Press down on the side gear. Install the pinion shaft and the lock screw. Use a thinner side gear thrust washer if you can not press the side gear down far enough to install the pinion shaft.
7. Rotate the pinion gear closest to the lock screw so that one of the teeth is pointing downward (perpendicular to the ring gear flange).
8. Insert a large tapered tool, such as a screwdriver, firmly between the side gear and the pinion shaft.





9. Mount and zero in a dial indicator to the ring gear flange. Place the stem of the indicator on one of the teeth of the pinion gear closest to the lock screw.
10. Pull the pinion gear firmly into the gear's seat. Rotate the gear back and forth while reading the dial indicator. Record the reading.
11. Repeat steps 7 through 9 for the opposite pinion gear.
12. The backlash should be between 0.051 - 0.243 mm (0.002 - 0.010 inch).
13. Use a thicker side gear thrust washer if the backlash is too high. Use a thinner washer if the backlash is too low.