Disassembly/Assembly of Drive Torque Controlled Differential

Disassembly/Assembly

Drive Torque Controlled Limited Slip Differential:

Legend 1:

Legend 2:

- Refer to images for instructions and legends.

Disassembly
- Remove pan head screws (Legend 1 no. 8) from case cover, remove cover and take out all internal components.
- Mark all thrust rings and differential shafts for reassembly.

Assembly
- Oil all sliding surfaces of the discs, thrust rings and differential shafts with transmission oil.





1 Cup spring
2 Outer disc
3 Inner disc
4 Thrust washer

- Install cup washers in such a way that the domed surface points towards the inside (towards the disc package).





A = Thrust ring (cover side)
B = Thrust ring (case side)





A = Thrust ring (cover side)
B = Thrust ring (case side)

- Install thrust rings and differential shafts in correct position.





- Determine thickness of disc package "d" (only required if components are to be replaced).





- Determine case depth, dimension "a".
^ Example: a = 106.35





Measurement I = e. g. 20.95 mm





Measurement II = e.g. 1.30 mm

- Determine dimension "b" of cover. Two measurements are required to determine this dimension.
^ "b" = Measurement I minus Measurement II
Example
I = 20.95 mm
II = 1.30 mm
___________
b = 19.65 mm

- Calculate clearance "c" inside casing.
^ c = a - b
Example
a = 106.35 mm
b = 19.65 mm
__________
c = 86.70 mm





A = Plate of Special Tool 9508/1

- Determine dimension "d" (disc package with 2.0 mm outer discs and inner discs but without cup springs).
^ Example 'd" = 81.50 mm





e/2 + e/2 = e = 5.2 mm

- Determine dimension "e" (must be 5.20 mm).
^ e = c - d
Example
c = 86.70 mm
d = 81.50 mm
___________
e = 5.20 mm

NOTE: If dimension "e" is exceeded or if the dimension remains below this value, fit thicker or thinner outer discs.
"e" below 5.20 mm - install thinner discs.
"e" above 5.20 mm - install thicker discs.

- Outer discs are available in a thickness of 1.9 mm, 2.0 mm and 2.1 mm.





A = Connecting piece (shop-made)

- Following assembly, measure spinning torque with one fixed shaft bevel gear and one driven shaft bevel gear. For this purpose. fit one flange with two bolts in a vise and position differential. Insert other flange with shop-made connecting piece and rotate differential with a torque wrench. A torque of 20-50 Nm (15-37 (ft lb) must be attained.