Limited Slip Differential - Disassemble
Disassembly Procedure
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| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | FT2563 | Differential Adjustment | 1 |
| B | 8T-5096 | Dial Indicator | 1 |
Start By:
- Remove the differential. Refer to Disassembly and Assembly, "Differential Axle - Remove and Install".
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Note: Before disassembly, measure the end play gap at both side gears independently. steps 1 through 7 cover the procedure for measuring end play gap.
- Place the differential assembly in the vise.
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| Illustration 1 | g00490940 |
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| Illustration 2 | g00490943 |
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| Illustration 3 | g00490967 |
- Insert Tooling (A) to the axle shaft of the differential assembly until the Tooling (A) passes through the side gear.
- Tighten the nut of Tool (A) enough to lock the tool on the internal shoulder of the side gear. The lever of Tool (A) must be free to move after the nut is tightened.
- Mount Tool (B) on the differential assembly, as shown. Zero the dial indicator of Tool (B) on Tool (A) .
- Apply 40 N·m (30 lb ft) of torque to Tool (A). The dial indicator reading is the measured end play gap at the side gear for the side opposite the bevel gear.
- Repeat step 1 through 5 for the other side.
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| Illustration 4 | g00491000 |
- Record both end play gaps. Replace the disc pack, if measurements are greater than 0.66 mm (0.026 inch).
Note: Steps 8 through 24 are for the disassembly of the differential.
- Remove twelve bolts (1) that secure bevel gear (2) to differential case (3) .
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| Illustration 5 | g00491040 |
- Install two bolts (1) in differential case (2). Do not tighten bolts (1). This will prevent differential case (3) from falling to the ground.
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| Illustration 6 | g00491082 |
- Use a press to separate bevel gear (2) from differential case (3) .
- Remove bevel gear (2) from differential case (3) .
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| Illustration 7 | g00491084 |
- Remove disc pack (4) .
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| Illustration 8 | g00491086 |
- Remove spacer (5) from the differential case.
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| Illustration 9 | g00491087 |
- Replacement of Disc kit consists of five plates (7), four friction discs (6), and spacer (5) .
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| Illustration 10 | g00491089 |
- Remove shim pack (8) from side gear (9) .
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| Illustration 11 | g00491092 |
- Use a micrometer to measure the thickness of the shim pack. Record the measurement for assembly purposes.
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| Illustration 12 | g00491093 |
- Remove side gear (9) from the differential case.
Note: Put identification marks on all parts for installation purposes. Do not switch parts to the other side.
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| Illustration 13 | g00491096 |
- Use a hammer and the punch to remove three dowel pins (10) from the differential case, as shown.
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| Illustration 14 | g00491097 |
- Remove pinion shaft (11) and two pinion shafts (12) from the different case.
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| Illustration 15 | g00491099 |
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| Illustration 16 | g00491101 |
- Remove four pinion gears (13), four thrust washers (14), and connector (15) from the differential case.
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| Illustration 17 | g00491102 |
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| Illustration 18 | g00491104 |
- Remove side gear (16) from the differential case.
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| Illustration 19 | g00491110 |
- Remove shim pack (17) from side gear (16) .
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| Illustration 20 | g00491111 |
- Measure the shim pack with a micrometer. Record the measurement for assembly purposes.
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| Illustration 21 | g00491112 |
- Remove spacer (18) from the differential case.
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| Illustration 22 | g00491114 |
- Remove disc pack (19) .
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| Illustration 23 | g00491115 |
- Replacement of Disc kit consists of five plates (22), four friction discs (21), and spacer (20) .
Note: Put identification marks on all parts for installation purposes. Do not switch parts to the other side.
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| Illustration 24 | g00491294 |
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