Author Topic: HOW TO: Restack Limited Slip differential clutches  (Read 2522 times)

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FunkyPhil

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HOW TO: Restack Limited Slip differential clutches
« on: July 07, 2014, 10:41:51 PM »
Pretty easy to do once the pumpkin is out.

TEARDOWN



I install the diff in a sturdy vise with the cover up.


Remove the 8 bolts with a 12mm socket and remove cover.


Now you can see the guts, notably the bearing caps.


I use a pointed punch to mark my caps. I mark closest to a bolt with either 1 or 2 dimples. Then again on the housing. This will prevent mixing or flipping your caps.





Use a 17mm socket to loosen them suckers. Once cap is removed, you will see the bearing race and shim. Keep those with the respective bearing


I stick something in this hole to pry the limited slip out. As you can see, you have access to a clutch here so be sure to avoid contacting it.






broken axle debris


Now use a 14mm socket to remove all the ring gear bolts.


A few well placed taps and off it comes.



Now that the ring gear is gone, you can access the 4 #3 (?) screws that hold it all together. Its wise to install lsd unit in some sort of captive device (vise, vise grips, etc) BEFORE loosening fasteners. The internals are in a state of compression and you dont want to damage the threads or yourself.


Now you can remove them.


You now have access to the disks and plates as well as the gear cluster.



I went into this diff for these 2 friction disks which I will be swapping out with friction plates on the other diff.


Now CLEAN YO SHIT!


87 Conquest Tsi: 519whp 519wtq 7.09@102--10.95@122
CLICK TO SEE BUILD

FunkyPhil

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Re: Differential clutch restack
« Reply #1 on: July 08, 2014, 09:25:30 AM »
REBUILD


Insert clutch stack into the ls housing



Right axle gear



Spider gears


Align pins with friction plate slots and drop in


rotate spiders into slots. it should drop down and seat in.


Install left axle gear and align with spider pins. Should close up almost completely.


Install clutches in reverse order of the first set. Mirror



once all the clutches are in, the last couple will be above the sealing surface. This is because the springs arent compressed.




I sit some of the ring gear bolts in the holes for alignment and then clamp sides together. Install the 4 housing screws and tighten until both surface touch.



Install ring gear and torque to 65ftlb


Install caps and torque to 47ftlb. MAKE SURE YOU USE THE SAME RACE AND SHIM ORIGINALLY ON THAT SIDE



Axle seals


Done!



FYI PICS

Welded spider gear





Center gear cluster minus top cup
87 Conquest Tsi: 519whp 519wtq 7.09@102--10.95@122
CLICK TO SEE BUILD

FunkyPhil

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Re: Restacking differential clutches
« Reply #2 on: July 08, 2014, 06:21:08 PM »
In the ER so I figured I would knock this out. Gotta love how photobucket keeps flipping my pics upside down.
87 Conquest Tsi: 519whp 519wtq 7.09@102--10.95@122
CLICK TO SEE BUILD

FunkyPhil

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Re: Restacking differential clutches
« Reply #3 on: July 09, 2014, 05:16:20 PM »
I went with a disk stack of
 )PDPD)-X-(DPDP(
(= spring
P= friction plate
D= friction disk

Outside springs on this stack are disk and inner springs are plates.

Stock stack is
((PPDP-X-PDPP))
This stack actually deactivates one friction surface reducing lockup by 33%

Manual shows stock stack as
((PDPD-X-DPDP)) which will restore full lock up.

Only problem I have with the stock stack is the springs are initially applying all their preload to the center of the friction clutches. Hopefully sandwiching the clutches between to opposing springs will bring in an equal preload.
87 Conquest Tsi: 519whp 519wtq 7.09@102--10.95@122
CLICK TO SEE BUILD