Differential Case Assembly

Exc. Limited Slip

1. Install side gear thrust washers and side gears into differential case.
2. Install pinion gears with washers into case. Rotate pinion gears to mesh with side gears.
3. Install pinion shaft. Do not install lock pin at this time.
4. Insert a wedge between side gear and pinion shaft to prevent side gear from turning, then install suitable dial indicator to gear and measure gear backlash. Backlash must not exceed .005 inch on rear differentials, or .006 inch on front differentials. If backlash is not within specifications, replace side gear thrust spacers as needed, then recheck backlash.
5. Align pinion shaft lock pin hole with differential case lock pin hole and drive lock pin into hole. Stake the lock pin in position in two places, using a suitable punch.
6. Remove adhesive tape from drive gear attaching bolts and the internal threads in gear.
7. Apply Loctite No. 271, or equivalent, to drive gear threaded holes, then install gear onto case with reference marks aligned. Torque attaching bolts alternately, in a diagonal pattern, to 58-65 ft. lbs.

Fig. 12 Finding dimension A.:

Limited Slip

1. Measure differential case depth (A), Fig. 12, (A=E - F+G).

Fig. 13 Measuring plate thickness.:

2. Measure spring disc and plate thickness using a suitable tool, with both extended in the same direction and one placed over the other as shown, Fig. 13. Arrange them so that the difference between left and right is minimized, then measure thicknesses of friction plates and discs in the same manner. Right side (Lr) and left side (Ll).
3. Measure thickness of left and right clutch plate assemblies and find the difference of the two. Difference should not exceed .002 inch. Clutch plate assembly thickness is thickness of spring, disc, spring plate, friction disc and friction plate.

Fig. 14 Finding dimension B.:

4. Assemble right and left friction plates, friction discs, pinion shafts and pressure rings, then measure total width (B), Fig. 14. Measure distance between clutch plates on a line with V-shaped groove in the pressure ring while pressing from both sides, ensuring groove is secured against pinion shaft. All parts should be dry.
5. Measure clearance between clutch plate and differential (S), then use the following formula: A(B+Lr+Ll).
6. If the difference (S) between the depth (A) of differential case and the overall width (B) obtained previously, plus the spring plate and spring disc assembly thickness is not within .002-.008 inch, replace friction discs to adjust.

Fig. 27 Finding thrust washer thickness.:

7. Measure distance (A), Fig. 27, then the depths of thrust washer contact surfaces, dimensions (C) and (D), in differential cases A and B.
8. Assemble pressure rings, pinion gears, side gears, pinion shafts and thrust washers.
9. Measure distance from back of left pressure ring to edge of thrust washer and ensure difference between the two does not exceed .002 inch. Measure distance between clutch plates on a line with V-shaped groove in the pressure ring while pressing from both sides, ensuring groove is secured against pinion shaft. All parts should be dry.

Fig. 28 Finding dimension R:

10. Measure overall width shown in Fig. 28, as dimension (R).
11. Using width of assembled differential unit and depth of differential case, measure clearance of side gear in axial direction. If clearance is not .002-.007 inch, replace thrust washers to adjust. Find clearance of side gear in axial direction using formula: A+C+DR.
12. Before assembly, apply a suitable lubricant to all contacting surfaces.

Fig. 16 Assembling differential clutch components.:

13. Assemble differential clutch and pinion assembly as shown, Fig. 16.
14. After assembly, measure rotating torque of assembly using tool No. MB990988. Turning torque should be 25-72 ft. lbs. for used clutch plates or 47-72 ft. lbs. for new clutch plates.
15. Remove old adhesive from drive gear attaching bolts, then apply a suitable sealer to bolts.
16. Insert and tighten bolts, then alternately torque to 58-65 ft. lbs.