Differential Case and Ring Gear - Model 60, Limited Slip
Differential Case and Ring Gear - Model 60, Limited SlipSpecial Tool(s):
Material:
Disassembly
NOTE: When refilling the axle with lubricant, first add 0.15L (6 oz) of friction modifier.
1. NOTE: It is not necessary to remove the differential bearings to overhaul the limited-slip differential.
NOTE: In most cases it is possible to disassemble the unit without removing the differential ring gear, which saves the cost of new bolts.
If necessary, remove the differential ring gear.
2. NOTE: An axle shaft held in a vise, with the shaft splines extending not more than 3 inches above the vise jaws, makes an excellent holding fixture for the differential case.
Remove the differential pinion shaft lockpin.
3. Using a hammer and drift, remove the differential pinion shaft.
4. Position the special tool in the bottom differential side gear bore.
^ Apply a small amount of grease to the special tool's centering hole.
5. Screw the special tool into the Step Plate.
6. CAUTION: Do not overtighten the special tool. Overtightening can damage the rear axle disc and plate kit.
Tighten the special tool enough to move the differential side gears away from the differential pinion gears and relieve the normal loaded condition.
7. Using a 0.762 mm (0.030 inch) thick piece of shim or gauge stock, push the differential pinion thrust washers out from behind the differential pinion gears and remove them.
8. NOTE: Carrying out this step releases pressure from the rear axle disc and plate kit.
Loosen the special tool.
9. NOTE: When attempting to rotate the differential side gears, tighten or loosen the special tool as necessary to permit gear movement.
Tighten the special tool until the differential pinion gears move slightly.
10. Insert the special tool into the differential pinion shaft bore. Rotate the differential case to position the differential pinion gears in the large differential case openings. Remove the differential pinion gears.
11. Hold the top differential side gear and rear axle disc and plate kit in the differential case and remove the special tool.
12. Continue to hold the differential side gear and the rear axle disc and plate kit and remove the special tool.
13. Remove the top differential side gear and the rear axle disc and plate kit.
14. Turn the differential case so that the flange or differential ring gear side is facing upward. Ease the special tool, differential side gear and rear axle disc and plate kit out of the differential case.
15. CAUTION: Keep the stack of clutch plates and clutch discs in the exact order as removed.
Remove the retainer clips from both rear axle disc and plate kits to allow separation of the clutch discs and clutch plates for cleaning and inspection.
16. Inspect these components.
^ The clutch plates and clutch discs for cracks, excessive wear and distortion. Install an entirely new stack of clutch plates and discs on both sides if discarding one or more of the clutch plates or clutch discs.
^ The differential pinion shaft and the differential case for excessive wear and pitting.
^ The differential side gear and differential pinion gear teeth.
Assembly
1. CAUTION: Always install an entirely new stack of clutch plates and discs on both sides if discarding one or more of the clutch plates or clutch discs.
Soak the clutch packs for 20 minutes in friction modifier.
2. CAUTION: Assemble the rear axle disc and plate kits to the differential side gears in exactly the same order as removed.
Prelubricate the differential side gear thrust faces and assemble the clutch plates and clutch discs onto the differential side gears.
^ Prelubricate each component of both stacks with rear axle lubricant or with friction modifier.
3. Assemble the retainer clips to the clutch plate ears. Both clips must seat completely onto the clutch plate ears.
4. NOTE: Hold the rear axle disc and plate kit to keep it from falling out of the differential case.
Install the rear axle disc and plate kit and differential side gear in the differential case.
^ The rear axle disc and plate kit must stay assembled to the differential side gear splines. The retainer clips must seat completely in the differential case pocket.
5. Install the bottom differential clutch pack and differential side gear in the differential case.
^ The rear axle disc and plate kit must stay assembled to the differential side gear splines. The retainer clips must seat completely in the differential case pocket.
6. Install the special tool.
^ Apply a small amount of grease to the special tool's centering hole.
7. Screw the special tool into the Step Plate.
8. Position the differential case onto the holding fixture.
9. Position both differential pinion gears opposite one another in the differential case. Align the differential pinion gear holes with each other. Hold the differential pinion gears in place by hand.
10. Tighten the special tool enough so that the differential side gears move away from the differential pinion gears and relieve the loaded condition.
11. NOTE: Slightly loosen or tighten the special tool to apply the necessary load to allow the differential side gears and differential pinion gears to rotate.
While holding the differential pinion gears in place, insert the special tool into the differential pinion shaft bore. Rotate the differential case until the holes of both differential pinion gears align with those in the differential case.
12. CAUTION: Do not overtighten the special tool. Overtightening can damage the rear axle disc and plate kit.
Tighten the special tool enough to allow clearance to assemble the differential pinion thrust washers.
13. NOTE: During assembly, the differential pinion thrust washer and the differential pinion gear holes must align exactly with those in the differential case.
Assemble the differential pinion gear thrust washers into the differential case.
^ Use a very small screwdriver to push the washers into place.
14. Remove all the tools from the differential case.
15. Install the differential pinion shaft.
16. Install the differential pinion shaft lockpin.
17. If removed, install the differential ring gear.
^ Tighten the Grade 9 bolts to 176 Nm (130 ft. lbs.)
