Self-locking limited slip differential. 1 - right side of the cup, 2 - thrust washers, 3 - friction clutch discs, 4 - shim, 5 - right spring holder, 6 - spring, 7 - left side of the cup, 8 - side gear, 9 - left spring holder, 10 - cross, 11 - satellite, 12 - thrust washer.
Note: Thrust washers marked are used only by the manufacturer and are not included in the scope of delivery of spare parts. When making adjustments, use suitable shims and thrust washers.
Note: thrust washers marked "asterisk", are thicker than other washers. These washers are only used by the manufacturer to adjust the backlash and are not included in the supplied parts kit. When repairing, replace the thrust washers with sets of thinner washers and adjust the backlash with shims.
Disassembly
1. Disassembly of the differential cup.
A) Mark the left and right sides of the differential cup.
b) Sequentially unscrew and remove 8 mounting bolts.
V) Using a plastic mallet, separate the left side of the differential cup from the right side.
2. Remove the following parts from the left side of the differential cup, side gear, set of thrust washers and friction clutch discs.
Note: Store removed parts separately to avoid confusion during reassembly.
2. Remove the following parts from the right side of the differential cup: left spring retainer, spring, spider with planets, right spring retainer, side gear, set of thrust washers and friction clutch discs.
Examination
1. Replace parts that are damaged or worn.
Note: If replacing the side gear, also replace the thrust washer that contacts the side gear.
2. Check thrust washers.
A) Check that the contact surfaces of the thrust washer are flat and not deformed.
Permissible thickness - 1.74 mm
b) Replace thrust washers if necessary.
Note: When replacing the thrust washer, also replace the friction clutch disc in contact with this washer.
3. Checking the discs of the friction clutch. Check disc for wear. Replace disk if necessary.
Attention: this friction clutch uses two types of discs, which are distinguished by a serrated notch on the outer edge or a double skip of teeth on the inner edge (right side of the picture) and the absence of these signs (left side of the picture). Be careful never to mix these types of discs in a differential when making replacements.
4. Check the free length of the spring.
Permissible spring length - 31.3 mm
5. A selection of shims,
A) measure distance "A" on the right side of the differential cup as shown.
b) Install a set of thrust washers and friction clutch discs on the side gear.
Note: Do not install shims.
V) Using a special tool, apply a 10 kg force to the set of thrust washers and friction clutch discs and measure the distance "IN".
G) Determine the total thickness of the shims using the formula:
"WITH" ="A" - "IN"- 16.15 mm
Note:
- Choose shims of similar thickness.
- Thrust washers (thickness marking A-M or 1-8) used by the manufacturer only.
They are not included in the scope of delivery of spare parts and do not have - Install shims between the outer thrust washer (marked "*") and a cup.
Thickness of shims - 0.15-0.35 mm (pitch 0.05 mm)
d) Similarly, select the shims for the left side of the differential cup.
Assembly
Note:
- Use a rag to clean the parts from dirt.
- Apply special oil to the contact surfaces of the clutch discs and thrust washers.
- When assembling the thrust washers (marking A-M or 1-8) are not used. Use a new thrust washer or shim to adjust the backlash.
1. Install the following parts in the left and right sides of the differential cup: shims (0-3 pcs.), friction clutch discs (4 things.), side gear thrust washers (5 pieces.), side gear.
Note: When installing, orient the thrust washers as shown in the assembly drawing.
2. Install the 4 satellites and thrust washers on the cross.
3. Align the holes in the right spring holder with the spider pins and install the holder.
4. Install the pinion and cross to the right side of the differential cup. Note: Press the cross into the right side of the cup without moving the spring holder.
5. Checking the backlash in the engagement of the side gear.
A) While holding the side gear and spider, measure the side gear backlash.
Side clearance - 0.05 - 0.20 mm
Note:
- The measurement is made on all four satellites.
- The measurement is carried out in the left and right parts of the differential cup.
b) If the backlash is too high or too low, install a different thickness shim.
6. Differential cup assembly.
A) Reinstall the cross and left spring retainer to the right side of the differential cup.
Note: Press the cross into the left side of the cup without moving the spring holder.
b) Install the spring and left spring retainer.
V) Install the side gear, thrust washers and friction clutch discs.
G) Align the marks and assemble the left and right parts of the differential cup.
Attention: be careful not to drop the side gears, check the alignment of the pinion and the side gear.
d) Tighten 8 bolts in sequence to the specified torque.
Tightening torque - 47 N.m