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Limited Slip Differential, Overhaul
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Code No. in housing: 4061 006 461....
Disassemble
Remove locking differential – see operation for "Dismantle
Differential". Use KM-161-3 (1) in conjunction with KM-621-18 (2)
to pull out both taper roller bearings. Attach the extractor hooks
from KM-161-3 (1) into the recesses (arrow).
Clamp limited slip differential using protective jaws and
unscrew fastening bolts (3, x 8) for ring gear. Drive off ring gear
with brass drift and remove.
Unbolt cover (5) from limited slip differential housing (4) and
remove.
 Clean
Remove all parts from limited slip differential housing and
clean.
Inspect
Check inner parts of limited slip differential for damage and
wear.
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Measure
Measure thickness of removed outer plates (1) and note value.
This is necessary if only inner and outer plates and no other inner
parts are being replaced.
Before final assembly of limited slip differential, measure
parts as described below.
Measure housing (2) with depth gauge and note value. This value
is designated "A" in the following calculation.
Measure height of collar (3) on housing and note value (D).
Measure depth of centre of cover to cover flange (4) and note
value (B).
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Assemble
Assemble all single parts as shown in illustration C 5702 using
new inner and, if necessary, new outer plates. The belleville
springs (arrows) are not installed here.
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Measure
Place preinstalled plate packet on housing. Measure height of
plate packet with depth gauge and note value (C).
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Calculation of outer plate thickness (when replacing inner/outer
plates and other parts)
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Housing depth, dimension (A)
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plus
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housing collar, dimension (F)
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=
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difference, dimension (F)
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Cover, dimension (B)
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plus
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difference, dimension (F)
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=
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sum
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sum
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minus
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plate pack, dimension (C)
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=
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difference, dimension (E)
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difference, dimension (E)
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minus
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thickness of spacer shim (2.5 mm + 0.2 mm tolerance)
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=
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play of plate pack in housing
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Play of 0.1 mm is permissible. If the play is larger, install
thicker outer plates. If the play is smaller, install thinner outer
plates.
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Sample calculation:
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Housing depth
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dim. (A)
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=
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86.7 mm
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minus
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Housing collar
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dim. (D)
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=
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3.5 mm
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Difference
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dim. (F)
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=
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83.2 mm
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plus
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Cover
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dim. (B)
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=
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5.7 mm
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sum
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=
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88.9 mm
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minus
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Plate pack
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dim. (C)
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=
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86.2 mm
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Difference
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dim. (E)
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=
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2.7 mm
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minus
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Thickness of differential shim
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=
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2.6 mm
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play of plate pack in housing
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=
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0.1 mm
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======
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Assemble
Then coat all inner parts thinly with special fluid and insert
in housing in correct order. Ensure that the belleville springs (1)
are installed with the hollow side to the plate pack.
Coat belleville spring (2) and thrust washer (3) thinly with
anti-friction bearing grease and insert in cover for limited slip
differential housing. Note recess in cover. Place cover on
differential housing.
Attach cover onto locking differential housing –
tightening torque 14 Nm / 10 lbf. ft.
Tension limited slip differential in vice using KM-621-25 (4).
Check slip torque.
Measure
Slip torque of limited slip differential – max. 5 Nm / 4
lbf. ft.
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Assemble
Place ring gear on a heating plate and heat to approx. 100
°C. To determine temperature, use thermochrome pencils or
suitable temperature gauge. After attaining temperature, place ring
gear on limited slip differential housing. Clamp limited slip
differential using KM-621-25 (2). Proceed swiftly so that the ring
gear does not cool down too much and stick to the flange.
Torque
Ring gear (1) to limited slip differential – 115 Nm / 85
lbf. ft.
Assemble
Press on both tapered roller bearings with KM-273 (3).
Install locking differential – see operation "Rear
Differential, Assemble".
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