Locking/Limited Slip Rear Axle
Locking Differential Cam Unit Disassemble (7 5/8 and 8.6 Assembly)Removal Procedure
1. Remove the retaining ring using snap ring pliers.
2. Remove the clutch plates and the guide clips.
Installation Procedure
1. Install the cam plate to the side cam gear.
2. Install the wave washer.
3. Install the clutch plates. Alternate the plates.
^ 7 5/8 ring gear = 8 plates
^ 8.6 ring gear = 10 plates
4. Install the retaining ring.
5. Install the guide clips and to the clutch plates. Use grease in the clips in order to hold the clips in place on the plates.
Locking Differential Cleaning and Inspection
1. Clean all of the parts using an approved solvent.
2. Visually inspect all the parts for excessive wear or breakage. Replace the parts if necessary.
3. Inspect the pinion gear and the side gear teeth for any of the following conditions:
^ Wear
^ Cracks
^ Scoring
^ Spalling
4. Inspect the thrust washer for wear.
5. Inspect the fit of the side gears on the axle shafts.
6. Inspect the differential case for cracks and scoring.
Important: Do not replace the thrust sleeve unless necessary.
7. Inspect the thrust sleeve for excessive wear.
8. Inspect the side gear bore for scoring. If scoring is present, replace the entire differential.
9. Replace the differential if you find any damage to the case.
Locking Differential Cam Unit Assemble
1. Install the cam plate to the side cam gear.
2. Install the wave washer.
3. Install the clutch plates. Alternate the plates as shown.
4. Install the thrust sleeve. Press the thrust sleeve flush with the side gear disc splines.
5. Install the guide clips to the clutch plates.
1. Use grease in the clips in order to hold the clips in place on the plates.
2. If the side cam gear or the side thrust sleeve has been replaced, measure and record the overall length of the gear assembly from the front of the gear to the back of the side thrust sleeve, including the side gear thrust washer.
3. Compare the reading with the reading obtained earlier.
4. If the new reading is more than 0.0762 mm (0.003 inch) higher or lower than the original, select a thrust washer that will return the reading closest to the original reading.
Locking Differential Adjustment
1. Assemble the clutch plates. Alternate the plates as shown.
2. Assemble the guide clips to the plates. Use grease in order to hold the clips in place on the plates.
3. Install the side gear thrust washer, the clutch plate assembly and the right side gear to the differential.
4. Place the pinion gears and the thrust washers into the differential.
5. Align the gears and the washers with the pinion shaft hole.
6. Press down on the side gear. Install the pinion shaft and the lock screw. Use a thinner side gear thrust washer if you cannot press the side gear down far enough in order to install the pinion shaft.
7. Rotate the pinion gear closest to the lock screw so that one of the teeth is pointing downward (perpendicular to the ring gear flange).
8. Insert a large tapered tool, such as a screwdriver, firmly between the side gear and the pinion shaft.
9. Mount and zero in a dial indicator to the ring gear flange. Place the stem of the indicator on one of the teeth of the pinion gear closest to the lock screw.
10. Pull the pinion gear firmly into the gear's seat. Rotate the gear back and forth while reading the dial indicator. Record the reading.
11. Repeat steps 7-9 for the opposite pinion gear.
12. The backlash should be between 0.051 - 0.243 mm (0.002 - 0.010 inch).
13. Use a thicker side gear thrust washer if the backlash is too high. Use a thinner washer if the backlash is too low.
Locking Differential Assemble
1. Install the left side gear thrust washer.
2. Install the cam unit.
3. Install the right side gear thrust washer.
4. Install the right clutch plates with the guide clips. Assemble the unit as shown.
5. Install the right side gear.
6. Install the thrust block, the pinion thrust washer, and the pinion gear.
1. Place the pinion gears into the differential 180 degrees apart.
2. Rotate the gears and the thrust block into position.
3. The open side of the thrust block must face the small window opening.
Important: Install a new lock screw, finger tight.
7. Install the pinion shaft.
8. Tighten to specifications after installation in the vehicle.
Important: The straight end of the latching bracket spring must be over and outside the governor assembly shaft.
9. Install the governor assembly and the latching bracket bushing.
10. Install the governor bushing.
1. Use the bushing with a straight hole, not tapered.
2. Press the bushing in far enough to give 0.1016 - 0.508 mm (0.004 - 0.020 inch) shaft end play.
11. Install the latching bracket bushing. Press the bushing in far enough in order to eliminate all of the end play.