40% Locking Differential

Disassembling




1. Unscrew socket head bolts on case cover and take off cover.
2. Take out all parts inside of case.

Assembling
1. Inspect all parts for wear or damage, replacing if necessary.
a) Differential Case:
Check guide grooves for outer plates and pressure rings for wear.
b) Pressure Rings:
Guide tabs and bearing surfaces must not be worn or scored excessively. They must also slide easily in the differential case.
c) Differential Gears:
Bearing surfaces for thrust washers must not be worn and inner plates must slide easily on splines of gears.
d) Plates:
Check inner and outer plates for wear. Guide tabs of outer plates and teeth of inner plates must not be worn.
2. Lubricate all sliding surfaces on plates, pressure rings and differential shafts with SAE 80 hypoid gear lube prior to installation.
3. Install thrust washers that retainers engage in bores of case or cover. It is recommended to hold washers in position with grease to make assembly work easier.
4. Install remaining parts as shown in the assembly drawing.

Note: Diaphragm springs must be installed that curved surfaces face out toward the joint flange.





1 Pressure ring
2 Inner plate
3 Outer plate
4 Diaphragm spring

Determining Thickness of Plate Assembly:
If new parts are used, the thickness of the plate assembly has to be determined again.




1. Measure case depth "a" with a depth gage.
Example: a = 77.50 mm.




2. Determine thickness "b" of plate assembly (with 2.0 mm thick outer plates, but without diaphragm springs). Clamp plate assembly in a vise lightly and measure distance "b" with a sliding calipers.
Example: b = 73.20 mm.




3. Figure out distance "e" (must be 4.2 mm). e = a-b

Example:
a = 77.50mm
b = 73.30mm
e = 4.2Omm
e2 + e2 = 4.20mm

Note: If determined distance is more or less than specified distance "e", install thicker or thinner outer plates.
"e" below 4.2 mm = use thinner plates. "e" above 4.2 mm = use thicker plates.
Outer plates are available in thicknesses of 1.9 mm, 2.0 mm and 2.1 mm.




4. After assembling, check slip torque with one differential gear held tight and one driven. This is done by clamping a flange with two bolts in a vise and placing the differential on it. Insert second flange with a locally made connector and turn differential with a torque wrench.
A torque of 10 to 35Nm must be reached.
A = Connector (made locally)

Note: Plates are worn and have to be replaced, if the specified torque is not reached with the thickest outer plates.