Limited Slip Differential
DISASSEMBLY
1. Place the holder J-39824 into a vise.
Position the differential on the holder with the ring gear side down.
2. Remove Lock pin (1) from differential shaft using a punch.
3. Remove Differential shaft (2) using hammer and punch.
Place shop towel behind case to prevent differential shaft from dropping out of case.
4. Assemble clutch pack unloading tool.
a. Install cap J-34174-1 to the bottom differential side gear.
b. Install threaded screw cap J-34174-2 to top differential side gear. Thread forcing screws J-22342-15 into threaded screw cap until it becomes centered into the bottom cap.
c. Tighten forcing screw until tight enough to collapse dished spacers and allow looseness between side and pinion mate gears.
5. Both pinion mate gear thrust washers using a shim stock (1) of 0.51 mm (0.020 inch) or equivalent tool to push out washers.
6. Relieve tension of dished spacers by loosening forcing screw.
Note:
- You may have to adjust the forcing screw slightly to allow the case to rotate.
7. Assemble LSD service adapter J-39834 onto long drive handle J-8592. Insert it into differential shaft hole of case. Pull on handle and rotate case until pinion mate gears can be removed.
8. Remove pinion mate gears.
9. Hold side gear top clutch pack (1) with one hand and remove Positraction unloading tools.
10. Remove top side gear and clutch pack.
Note:
- Keep the stack of plates and discs intact and in exactly the same position while they are being removed.
11. Remove case from holder. Turn case with flange or ring gear side up to allow side gear and clutch pack to be removed from case.
12. Remove differential plate retainer from both clutch packs to allow separation of the plates and discs.
Note:
- Keep the discs and plates in the same order as they were removed.
INSPECTION AND REPAIR
Cleaning
- All parts with solvent.
Visual Inspection
- Clean all parts with solvent.
- Plates and Discs. If any one disc or plate in either stack shows evidence of excessive wear or scoring, the complete stack is to be replaced on both sides.
- Side Gears and Pinion Mate Gears. The gear teeth of these parts should be checked for extreme wear and possible cracks. The external teeth of the side gear, which retain the concentric groove discs, should also be checked for wear or cracks.
- If replacement of one gear is required due to wear, etc., then both side gears, pinion mate gears, and thrust washers are to be replaced.
- Differential Shaft. If excessive wear is evident, the differential shaft should be replaced.
- Differential Plate Retainers. If wear is evident on any one of the differential plate retainers, all four retainers must be replaced.
- Differential Case. If scoring, wear or metal pickup is evident on the machined surfaces, replacement of the case is necessary.
REASSEMBLY
1. Lubricate thrust face of side gears, plates and discs with the proper limited slip rear axle lubricant.
2. Assemble plates and discs in exactly in the same position as they were removed, regardless of whether they are new or original.
3. Install differential plate retainer to ears of plates.
Note: Make sure both retainers are completely seated on ears of plates.
4. Install clutch pack and side gear into bottom side gear bore. Make sure clutch pack stays assembled to side gear splines, and that retainers are completely seated into pockets of case.
Note: To prevent clutch pack from failing out of case, hold clutch pack in place by hand while repositioning case on bench.
5. Install other side gear and clutch pack. Make sure clutch pack stays assembled to side gear splines, and retainers are completely seated into pockets of case.
6. Hold clutch pack in position and assemble screw cap J-34174-2, cap J-34174-1 and forcing screw J-22342-15. Tighten forcing screw into bottom cap to hold both clutch packs in position.
7. With tools assembled to case, position case on holder J-39824 by aligning splines of side gear with those of shaft. Tighten forcing screw to compress clutch packs in order to provide clearance for pinion mate gears.
8. Install pinion mate gears.
- Place the pinion mate gears into the differential 180 degrees apart.
9. While holding gears in place, insert LSD service adapter J-39834 with long drive handle J-8592 in differential shaft hole of case. Pull on long drive handle J-8592 and rotate case, allowing gears to turn. Make sure that holes in pinion mate gears align with holes in case.
- It may be necessary to adjust tension on forcing screw to rotate case.
10. Tighten forcing screw to compress the clutch packs, to allow installation of spherical thrust washers.
11. Lubricate spherical thrust washers (2), and assemble into case (1). Use a small screw driver to push washers into place. Remove tools.
12. Position differential shaft in case and drive in with hammer. Be sure lock pin hole of differential shaft (5) is properly aligned to allow installation of lock pin (3). Be sure that thrust washers and differential pinion mate gears are aligned with the differential case (4). Install new lock pin to proper depth using a punch.
Stake metal of case over pin in two places, 180 degrees apart.