Usage:
Start By:
a. remove differential
NOTE: The following procedure is for the disassembly of TRACTECH INC. Limited Slip Differentials.
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.
Correct Position Of Tool (A)
1. Place the differential assembly in a vise.
2. Insert Tool (A) in the axle shaft bore of the differential assembly until it passes through the side gear.
3. 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.
4. Mount Tool (B) on the differential assembly, as shown. Zero the dial indicator of Tool (B) on Tool (A).
5. 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.
6. Repeat Steps 1 through 5 to measure the end play gap at the side gear for the side adjacent to the bevel gear.
7. Record the end play gap measurements taken from each side of the differential. If either of the end play gap measurements are greater than 0.66 mm (.026 in), replacement of the disc packs is necessary.
NOTE: Steps 8 through 24 are for the disassembly of the differential.
8. Remove the twelve bolts (1) that secure bevel gear (2) to case housing (3).
9. Install two bolts (1) in the case housing. Do not tighten bolts (1). This will prevent the case from falling when separated from the bevel gear.
10. Use a press to separate bevel gear (2) from case housing (3).
11. Remove bevel gear (2) from case housing (3).
12. Remove disc pack (4).
13. Remove friction spacer (5).
Replacement Disc Kit
NOTE: A replacement disc kit consists of five plates (7), four friction discs (6), and one friction spacer (5).
14. Remove shim pack (8) from side gear (9).
15. Use a micrometer to measure the thickness of the shim pack. Record the measurement for assembly purposes.
16. Remove side gear (9).
NOTE: Identify all parts removed from the side adjacent to the bevel gear before continuing disassembly. Do not mix parts from side to side.
17. Use a hammer and punch to remove three dowel pins (10) from the case housing, as shown.
18. Remove pinion shaft (11) and two pinion shafts (12) from the case housing.
19. Remove four pinion gears (13), four thrust washers (14), and connector (15) from the case housing.
20. Remove side gear (16) from the case housing.
21. Remove shim pack (17) from side gear (16).
22. Measure the shim pack with a micrometer. Record the measurement for assembly purposes.
23. Remove friction spacer (18).
24. Remove disc pack (19).
NOTE: A replacement disc kit consists of five plates (20), four friction discs (21), and one friction spacer (18).
NOTE: Identify all parts removed from the side opposite the bevel gear. Do not mix parts from side to side.
Assemble Limited Slip Differential (914G & IT14G)
1. Clean and inspect all parts of the differential. If any of the parts are worn or damaged, use new parts for replacement.
- a. Either of the end play gap measurements recorded in Step 7 of the disassembly is greater than 0.66 mm (.026 in).
- b. Disc friction material is worn such that the discs, or areas of the discs, are running steel on steel.
2. Replace the disc kits if:
NOTE: Two new shim packs will be needed to properly adjust the end play gap. Each new shim pack consists of two shims 0.46 mm (.018 in), two shims 0.38 mm (.015 in), two shims 0.33 mm (.013 in), and two shims 0.25 mm (.010 in).
3. Use clean axle oil to thoroughly lubricate plates (20), friction discs (21), and friction spacer (18), prior to assembly.
4. Install disc pack (19) in alternate order in the case housing. Start with a plate and end with a plate.
5. Install friction spacer (18) in the case housing with the friction material side down.
NOTE: Apply a small amount of grease to the shims prior to installation. This will retain the shims in place when the gear is installed.
6. Install new shim pack (17) of the same thickness from Step 22 of the disassembly on side gear (16).
7. Invert side gear (16) and install in the case housing, as shown. Make certain the shims remain in place while installing side gear (16).
NOTE: Turn side gear (16) slowly until the spline engages with the friction spacer and all five friction discs. Make sure the gear is fully seated.
8. Install connector (15), four pinion gears (13), and four thrust washers (14) in the case housing.
9. Lubricate pinion shafts (11) and (12) with clean axle oil.
NOTE: It is acceptable to use a small amount of force to install the pinion shafts.
10. Align the pinion gears and thrust washers with the pinion shaft bores in the case housing. Install pinion shafts (11) and (12).
11. Install three dowel pins (10) in the case housing to anchor pinion shafts (11) and (12).
12. Use clean axle oil to thoroughly lubricate plates (7), friction discs (6), and friction spacer (5), prior to assembly.
13. Place bevel gear (2) on the bench with the gear teeth facing up, as shown.
14. Install disc pack (4) in alternate order in the bevel gear. Start with a plate and end with a plate.
NOTE: Disc pack (4) consists of five plates and four friction discs.
15. Install friction spacer (5) in the bevel gear with the friction material side down.
NOTE: Apply a small amount of grease to the shims prior to installation. This will retain the shims in place when the side gear is installed.
16. Install a new shim pack (8) of the same thickness from Step 15 of the disassembly on side gear (9).
17. Invert side gear (9) and install in the bevel gear, as shown. Make certain the shims remain in place while installing the side gear.
NOTE: Turn side gear (9) slowly until the spline engages with the friction spacer and all five friction discs. Make sure the gear is fully seated.
18. Install Tooling (C) on bevel gear (2) and side gear (9), as shown. This will retain the side gear, shims, friction spacer, and disc pack in the bevel gear during the installation of the bevel gear on the case housing.
NOTE: The clamping segment of Tooling (C) must not protrude past the face of side gear (9).
19. Invert bevel gear (2) and carefully install on case housing (3).
NOTE: The bevel gear is a light press fit to the case housing. It is important to tighten bolts (1) evenly in order to properly seat the bevel gear.
20. Install twelve bolts (1).
21. Tighten bolts (1) evenly until bevel gear (2) is seated on case housing (3).
22. Remove the nut and cap of Tooling (C).
23. Loosen the clamping segment of Tooling (C) and remove it from the differential assembly.
24. Tighten bolts (1) to a torque of 300 ± 40 N·m (220 ± 30 lb ft).
NOTE: Steps 25 through 34 are for measuring the end play gap.
Correct Position Of Tool (A)
25. Place the differential assembly in a vise.
26. Insert Tool (A) in the axle shaft bore of the differential assembly until it passes through the side gear.
27. 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.
28. Mount Tool (B) on the differential assembly, as shown. Zero the dial indicator of Tool (B) on Tool (A).
29. 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.
30. Repeat Steps 25 through 29 to measure the end play gap at the side gear for the side adjacent to the bevel gear.
31. Record the end play gap measurements taken from each side of the differential.
32. The measured end play gap for each side of the differential must fall between 0.05 mm and 0.15 mm (.002 in and .006 in) to meet specifications.
33. If the measured end play gap for either side of the differential is greater than 0.15 mm (.006 in) disassemble the differential and add the necessary shims to meet specifications.
34. If the measured end play gap for either side of the differential is less than 0.05 mm (.002 in) disassemble the differential and remove the necessary shims to meet specifications.
End By:
a. install the differential