Limited Slip & Rear Differential Lock

Fig. 7 Differential Case Depth Measurement:

1. Measure differential case depth (A), Fig. 7, using formula A = E - F + G.

Fig. 8 Plate Thickness Measurement:

2. Measure spring disc and plate thickness with both extended in the same direction and one placed over the other as shown, Fig. 8. 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, then find the difference of the two. Difference should not exceed 0.002 inch. Clutch plate assembly thickness is thickness of spring, disc, spring plate, friction disc and friction plate.

Fig. 9 Total Width Measurement:

4. Assemble right and left friction plates, friction discs, pinion shafts and pressure rings, then measure total width (B), Fig. 9. 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 0.002-0.008 inch, replace friction discs to adjust.

Fig. 10 Thrust Washer Thickness Measurement:

7. Measure distance (A), Fig. 10, 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 0.002 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. 11 Dimension "R":

10. Measure overall width shown in Fig. 11, 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 .002-0.007 inch, replace thrust washers to adjust. Find clearance of side gear in axial direction using formula: A + C + DR.
12. Before assemble, apply lubricant to all contacting surfaces.

Fig. 12 Differential Clutch Component Assembly:

13. Assemble differential clutch and pinion assembly as shown, Fig. 12.
14. After assembly, measure rotating torque of assemble using tool No. MB990988, or equivalent. 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 sealer to bolts.
16. Install and finger tighten bolts, then alternately torque to 58-65 ft. lbs.