Vehicles before change point in 1982
DISASSEMBLING AND ASSEMBLING
LOCKING DIFFERENTAL
(locking differential removed)
Unscrew case cover mounting bolts.
Take off case cover.

Turn case upside down and let contents slide
out.
Apply light knocks against case if necessary.

Order of Installation:
1 thrust washer, 2 diaphragm spring, 3 stepped
washer, 4 spacer, 5 diaphragm spring, 6 outer
plate, 7 inner plate, 8 pressure ring, 9 differential
side gear, 10 differential gear, 11 differential
shaft, 12 case and 13 cover.
Check all parts for scoring.
Pressure rings must move easily in case.
Guide tabs of pressure rings and outer plates
must not be worn.
Inner plates must move easily on spline.
Splines must not be worn.
Replace worn thrust washers, stepped
washers and plates.

Adjust axial play of differential side gears after
replacement of thrust washers and stepped
washers.
Install following parts in case one after the
other.
(8) pressure ring, (9) differential side gear,
(10) differential gear, (11) differential shaft.
Check distance A from case edge to differential
side gear, e.g. A = 5.40 mm (0.212´´).

Measure distance B on cover,
inside, e.g. .............................8.50 mm (0.335´´)
Measure distance C on cover,
outside, e.g. .........................- 2.90 mm (0.114´´)
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Sum of B - C = D.....................5.60 mm (0.221´´)
Sum of D + A .........................5.40 mm (0.212´´)
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E = .......................................11.00 mm (0.433``)

Take half of distance E (11.00 mm (0.433´´).
Install thrust washers having thickness of 5.50 mm
(0.216´´) less 0.10 mm (0.004´´) on each
side (0.10 mm/0.004´´ is required to prevent
pressing diaphragm springs flat). Thrust washers
(stepped washers) are available in steps of 0.05 mm
(0.002´´).
Example:
1 Thrust (stepped) washer... 2.20 mm (0.087´´)
2 Diaphragm spring ............. 1.10 mm (0.043´´)
3 Thrust washer .................. 2.10 mm (0.082´´)
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Each side............................. 5.40 mm (0.212´´)

Install following parts in case one after the other.
Spacer (4), outer plate (6), inner plate (7),
pressure ring (8), differential side gears (9),
differential gears (10) and differential shafts (11).
Measure distance A from case edge to outer
plate, e.g. A = 8.20 mm (0.323´´).

Measure distance B on cover,
e.g. B = 2.90 mm (0.114´´).

Install both diaphragm springs with their
concave sides facing same direction.
Measure distance C on diaphragm springs,
e.g. C = 5.0 mm (0.197´´).

An installed clearance of 0.1 to 0.4 mm (0.004 to
0.016´´) is required to prevent pressing diaphragm
springs flat.
Example:
B (cover) .......................2.9 mm (0.114´´)
C (diaphragm springs)...+5.0 mm (0.197´´)
________________________________
.......................................7.9 mm (0.311´´)
A (case) .........................8.2 mm (0.323´´)
B + C ............................-7.9 mm (0.311´´)
________________________________
D installed clearance ....0.3 mm (0.012´´)
Deviations from installed clearance D can be
corrected with outer plates (1) of proper
thickness.

Remove all parts from housing.
Installation: Install thrust washer (1) with its
oil pocket facing up.
Concave side of diaphragm spring (2) faces
differential shaft.
Smooth side of thrust (stepped) washer (3)
faces diaphragm spring and tab is in opening.

Install spacer (4), diaphragm spring (5) WITH
concave side facing differential shaft, outer
plate (6) and inner plate (7).
Important: Outer plates determine the slip
torque.
Use outer plate (6) in thickness of 1.9, 2.0 or
2.1 mm (0.075, 0.079 or 0.083´´).

Install pressure ring (8).
Turn differential side gear (9) to have it engage
in spline of inner plate.

Install differential gears (10) with differential
shafts (11).

Install differential side gear (9) and pressure
ring (8).

Install inner plate (7), outer plates (6) with the
thinner outer plate first and diaphragm spring
(5) with its concave side facing differential
shaft.

Install thrust washer (1) with its oil pockets
and diaphragm spring (2) with its concave side
facing differential shaft.
Install thrust (stepped) washer (3) with its
smooth side facing diaphragm spring and
lubricate with grease.
Install cover and tighten bolts uniformly.

Check slip torque¹) while holding one differential
side gear and turning the other.
Make up tool for this purpose locally.


¹) See Specifications