Disassembling/Assembling Limited Slip Differential

Disassembling/Assembling

Limited Slip Differential:

Legend 1:

Legend 2:

Legend 3:

- Refer to images for instructions and legends.





NOTE: If equipped with Gylon inner discs, the limited-slip differential must be modified to accept Valeo inner discs when repairs are required. To do so, fit all inner and outer discs, cup spring, and thrust ring. Adjust pack thickness to specified value of 37.9 ± 0.1 mm . Also mark the modified transmissions for identification (to highlight different wear limits) by stamping a large "V" into the transmission housing (below the lock cylinder).

Assembly with Gylon Discs





NOTE: Determine axial play of differential bevel gears and adjust to 0.05-0.15 mm by inserting appropriate friction washers (A).





A = Friction washers

NOTE: If components have been replaced (e.g. differential housing or bevel gears), the thinnest friction washers must be installed for measurement.





B = Dowel pin

- Drive in dowel pins for bevel-gear axles in correct position.





- Determine thickness of block of plates.
^ Block thickness (new) = 36.7t 0.1 mm
^ Wear limit = 34.2 mm
- Measure complete block of plates (without pressure ring) with Special Tool 9508/1 and adjust to prescribed size with adjusting plate (No. 22) if necessary.

Example
Measured value 117.80 mm
Height of special tool - 81.50 mm [1]
___________
Thickness of block 36.30 mm

[1] Embossed on tool

- Adjusting plate must be 0.4 mm thicker.





A = Missing tooth
B = Spiral groove
C = Oil hole

- Apply film of transmission oil to inner plate and assemble in such a way that the spiral groove for the oil supply runs clockwise from inside to outside when looking at the block of plates (direction of assembly) (refer to simplified sketch). Apart from this, the oil holes in the carrier sheet must be exactly in line with one another. Assembly is easier if a tooth is missing from the carrier plate.
- Assemble differential lock assembly completely to adjust basic locking moment (with deep-groove ball-bearing and tapered-roller bearing inner races).





A = Connector (produced locally)

- Measure breakaway torque with one bevel gear held fast and one driven. For this, clamp a flange with two screws into the vice and measure the torque at the other flange.
- Adjust breakaway torque with hook wrench by turning the ring nut to 100 Nm (73.75 ft lb), then undo ring nut as far as the safety groove at which the breakaway torque is less than 20 Nm (15 ft lb).





C = Tab washer

- Secure ring nut with tab washer.

Assembly with Valeo Friction Linings

Disc Pack:

Legend:

NOTE: Following the change of the inner discs from Gylon to Valeo, stacking, adjustment and wear limit specifications of the disc pack have been modified.

Former Gylon Disc:

New Valeo Disc:

- Determine thickness of disc pack.
^ Pack thickness (new) = 37 9 + 0.1 mm
^ Wear limit = 36.5 mm





- Measure entire disc pack with cup spring (but without thrust ring).

Example
Measurement 117.90 mm
Special Tool height -81.50 mm [1]
___________
Pack thickness 36.40 mm

[1] Engraved on tool

NOTE:
- If the wear limit has been reached, all inner discs must be replaced and the disc pack must be packed with the outer discs towards the cup spring to give a pack thickness of 37.9 + O.1 mm.
- A maximum of two outer discs may be fined at the cup spring. The outer disc in contact with the cup spring must have a minimum thickness of 1.5 mm.

- Coat discs with transmission oil before fitting them.
- Oil bores in carrier plate of inner discs must line up exactly.