Limit Slip Differential
Disassembly
Differential Cages A and B
1. To ensure installation of the parts in original position apply a setting mark before removing the differential cages A and B.
2. Using special tool, J-44450, grip it with a vice, and set the differential.
3. Gradually and evenly loosen the 3 fixing screws of the differential cages A and B.
4. Remove differential cage A.
5. Remove thrust washer.
6. Remove spring disc.
Note: When removing the spring disc, friction disc, and friction plate, place them in order for clear distinction left and right use.
7. Remove Friction disc.
8. Remove friction plate.
9. Remove friction plate.
10. Remove friction disc.
11. Remove friction plate.
12. Remove friction disc.
13. Remove friction plate.
14. Remove pressure ring.
15. Remove side gear.
16. Remove pinion and pinion shaft.
17. Remove side gear.
18. Remove pressure ring.
19. Remove friction plate.
20. Remove friction disc.
21. Remove friction plate.
22. Remove friction disc.
23. Remove friction plate.
24. Remove friction plate.
25. Remove friction plate.
26. Remove friction disc.
27. Remove thrust washer.
28. Remove differential cage B.
Inspection and Repair
Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition is found through inspection.
Visual Check
Check ten following parts for wear, damage, noise or any other abnormal conditions.
^ Friction disc, friction plate and spring disc.
^ Pressure ring
^ Thrust washer
^ Case
Measure the deformation of the friction disc & plate.
Limit: 0.08 mm (0.003 inch)
Measure the wear of the friction plate & disc.
Limit (A-B): 0.1 mm (0.004 inch)
Remarks:
A= Inner or outer projections
B= Sliding surface subjected to abrasion
Measure the wear of the thrust washer.
Limit: 1.3 mm (0.05 inch)
Reassembly
Adjust the clearance between the friction disc and plate.
1. Measuring the depth of the differential cage.
Standard
(A-B): 89.13 mm (3.51 inch)
(C): 9.13 mm (0.36 inch)
2. Measuring the overall length of the pressuring friction disc and friction plate.
^ Mount the pinion shaft in the pressuring and then install the friction disc & plate.
^ Measure the length between the plates over the V-groove (D).
3. After measuring dimensions A, B, C and D, make adjustment in the following manner:
^ Measure the thickness (E) of the spring disc.
1.75 mm (0.069 inch) X 2 discs
4. Select the friction disc & plate so as to satisfy the following equation: ((A - B) + C) - (D + E) = 0.06 - 0.20 mm (0.002 - 0.008 inch)
Also, the total size difference of the friction disc & plate and spring disc should be 0.05 mm (0.02 inch) or less.
Thickness: 1.65 - 1.75 - 1.85 mm (0.065 - 0.069 - 0.073 inch)
Backlash adjustment of the side gear in the direction of the shaft
1. Measuring the depth of the differential cage.
(F-B): 95.63 mm (3.76 inch)
(G): 15.63 mm (0.62 inch)
2. Measuring the dimension between the thrust washers at both ends.
^ Assemble the side gear, pinion, pinion shaft, pressure ring and thrust washer, and pressing the pressure ring to the pinion shaft in the direction of the shaft to make clearance 0.
^ Have the side gear contact to the pinion to make the backlash 0.
^ Measure the dimension (H) between thrust washers at both ends.
3. After measuring dimensions of each of the above sections, proceed with the adjustment in the following manner:
^ Adjust the clearance to satisfy the equation.
((F - B) + G - H) = 0.05 - 0.20 mm
Also, select the thrust washers so that the dimensional difference between the back surfaces of the left and right pressure rings to the thrust washers is 0.05 mm or less.
Thickness:
1.5 mm (0.059 inch)
1.6 mm (0.063 inch)
1.7 mm (0.067 inch)
Note: when assembling the parts, apply recommended gear oil sufficiently to each of the parts, especially, to the contact surfaces and sliding surfaces.
1. Install differential cage B.
2. Install thrust washer.
3. Install spring disc.
^ When assembling the spring disc, make sure the mounting direction is correct as shown in figure.
4. Install friction plate.
5. Install friction plate.
6. Install friction plate.
7. Install friction disc.
8. Install friction plate.
9. Install friction disc.
10. Install friction plate.
11. Install pressure ring.
12. Install side gear.
13. Install pinion and pinion shaft.
14. Install side gear.
15. Install pressure ring.
16. Install friction plate.
17. Install friction disc.
18. Install friction plate.
19. Install friction disc.
20. Install friction plate.
21. Install friction plate.
22. Install friction plate.
23. Install spring disc.
^ When assembling the spring disc, make sure the mounting direction is correct.
24. Install Thrust washer.
25. Install Differential Cage A.
26. Install Screw.
^ Matching the guide marks of the differential cages A and B. tighten the screws evenly in the diagonal order.
28. Check the operation.
^ Measure the starting torque using the side gear holder.
Starting Torque: 29 - 45 Nm (3.0 - 4.6 kgf/22 - 33 ft. lbs.)