Locking Differential
SPECIAL TOOLS
DISASSEMBLY
Refer to "Disassembly of The Rear Axle" for removing differential case assembly from housing. Service and Repair
DIFFERENTIAL DISASSEMBLY RING GEAR
Tools Required: J-39858; Clutch pack unloading tool kit
1. Place the holder of J-39858 into a vise. Position the differential on the holder with the ring gear bolts facing up.
NOTE: Place shop towels over the vise to prevent any damage during disassembly of the ring gear. Whenever the ring gear bolts are removed, they should be replaced with new ones. of the ring gear.
UNIT
Tools Required: J-39858; Clutch pack unloading tool (Forcing screw, screw cap & cap and LSD service adapter). J8592 Long Driver Handle
1. Reposition differential case onto shaft.
2. Lock pin from differential shaft using a punch.
3. Differential shaft using hammer and punch. Place shop towel behind case to prevent differential shaft from dropping out of case.
INSTALLATION
a. The tools of screw cap and cap to the bottom differential side gear.
b. Threaded adapter plate to top differential side gear. Thread forcing screws into threaded adapter until it becomes centered into the bottom adapter plate.
c. Tighten forcing screw until tight enough to collapse dished spacers and allow looseness between side and pinion gears.
4. Both pinion gear thrust washers using a shim stock of 0.51 mm (0.020 in.) or equivalent tool to push out washers.
5 Relieve tension of dished spacers by loosening forcing screw.
ADJUSTMENT
NOTE: You may have to adjust the forcing screw slightly to allow the case to rotate.
6 Assemble LSD onto long drive handle (J-8592). Insert into differential shaft hole of case. Pull on handle and rotate case until pinion gears can be removed.
7. Pinion gears.
8. Hold side gear top clutch pack with one hand and remove positraction unloading tools.
9. 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.
10. Remove case from shaft. Turn case with flange or ring gear side up to allow side gear and clutch pack to be removed from case.
11. 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
- 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 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 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
UNIT
1. Lubricate thrust face of side gears, plates and discs with the proper limited slip rear axle lubricant.
2. Plates and discs in exactly in the same position as they were removed, regardless of whether they are new or original.
3. Differential plate retainer to ears of plates.
NOTE: Make sure both retainers are completely seated on ears of plates.
4. 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 packets of case.
NOTE: To prevent clutch pack from falling out of case, hold clutch pack in place by hand while repositioning case on bench.
5. 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 insert screw cap & cap and forcing screw. Tighten forcing screw into bottom adapter to hold both clutch packs in position.
7. With tools assembled to case, position case on yoke shaft by aligning splines of side gear with those of shaft. Tighten forcing screw to compress clutch packs in order to provide clearance for pinion gears.
8. Pinion gears.
- Place the pinion gears into the differential 180 degrees apart.
9. While holding gears in place, insert LSD service adapter 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 gears align with holes in case.
- It may be necessary to adjust tension on forcing screw to rotate case.
ADJUSTMENT
10. Tighten forcing screw to compress the clutch packs, to allow installation of tapered washers.
11. Lubricate spherical washers, and assemble into case. Use a small screwdriver to push washers into place. Remove tools.
12. Position differential shaft in case and drive in with hammer. Be sure retaining pin hole of differential shaft is properly aligned to allow installation of retaining pin. Be sure that thrust washers and differential pinion gears are aligned with the differential case. Install new retaining pin to proper depth using a punch. Stake retaining pin at both ends of case.