Removal and Installation

LIMITED SLIP DIFFERENTIAL (LSD)
REMOVAL





1. Using the torx screw driver #T27, remove the 4 torx screws on the flange.

NOTE:
^ Before removal, make matchmarks.





^ If the case halves are not separated, tap the heads of the screws lightly with a punch and a hammer.





2. Remove the screws, left hand side case, left hand side case shim, left hand side case gear sub-assembly (side gear, disc pack, and ear guides), preload plate and two preload springs from the right hand side case assembly.

NOTE: Keep these parts separate so that they can be reassembled in the same location as they were originally.





3. Drive out the cross shaft lock pin using a 4 mm diameter rod and a hammer.





4. Remove the cross shaft from the side gear.

NOTE: The cross shaft must be driven toward the side where the lock pin hole is located.





5. Follow the same procedure for the opposite side case.

NOTE: Do not mix R.H. and L.H. parts.

INSPECTION
1. Check the side gears, pinions, pinion thrust washers, and cross shaft for wear or damage. If there is excessive wear, cracks, nicks, grooves or galling, replace the parts.
2. Inspect the carbon surfaces. After cleaning with a solvent, the carbon surface should appear a course weave fabric with flat spots on the peaks of the weave. If the surface is smooth, either from wear or from the weave filled with debris, replace the entire disc pack.





3. Measure the thickness of the carbon friction discs. If the measurements is below the limit value, replace the disc.
4. Inspect the splined friction discs. If they have grooves or are polished, replace the entire disc pack. Small scratches on them are O.K.

SHIM SELECTION FOR CLUTCH DISC
1. Measurement for right hand side pocket. Measure the right hand side pocket with the pinion shaft installed.





2. Measurement for left hand side pocket Measure the left hand side pocket with the pinion shaft installed according to the following formula.

LEFT HAND SIDE POCKET = A + B - C





3. Measurement for the side gear sub height.
Install the clutch disc, side gear, preload spring and spring plate, and then adjust the clearance of the preload spring by applying the pressure at both sides till it is 32 mm. At this time, measure the height of side gear sub at right and left hand sides by measuring the length of "D".
4. Selecting shims by the side gear sub height
a. Used disc
Shim thickness = RH(LH) pocket - RH(LH) side gear sub height - 6.45
b. New disc
Shim thickness = RH(LH) pocket - RH(LH) side gear sub height - 6.20
LH: Left hand side, RH: Right hand side

NOTE:
^ Adjust the shim thickness within 0.08 mm.
^ When replacing one disc, replace all of the discs.





5. The specifications of the clutch disc shim