Limited Slip Installation Manual
Contents
1. 4 Auburn Gear A Auburn Gearf LIMITED SLIP A DIFFERENTIAL uburn Gear Inc INSTALLATION MANUAL MH 553 LSI 2010 1 8SECSOT doqunN died WD VOPSASICV3D LQUMN JIE PIOA Joneyo VINJI JENUJIJJJJIP asneo Aew sad ro pue JADIppe 19410 JO SSA BAOQK pagiiosap SATIIppe pur IO JU osn JIULUUOJJOA UNUNAO Io pue 9SIOU Iye yomo JENUJJJJJIP prose oL po JO JIeNb won JJIM JANIPPE JO zo SOAIJIPPE UOJ PIOA 10 JAD YIM powan spro prodAy 06M08 JIJSUJUA Ss U0U yjenb ysy UJIM polso JSAISU9JX9 u q sey USIS9P JENUJJJJJIP JIJS POJIUNJ IaH UINGNV su ALON INVDIUATI INVLYOdINI JOSUO OU UBI JI PAJJEJSUL 1095 Suu e 10 pue SSULIeJq pey sey JENUJJJJJIP ET 3900 QUO J991109 Y 10 JENUVJJJJIP JU FULYIXI 07 sUIW JULIE JESSJJ9U JU IJLU pue aseyoInd zo Jsejd JNOA J9EJU09 uoneordde MOA 10 JENUJJJJJIP FUOIM JU DALY NOK WY 99 NOA JI pormbol SI yey SIS ISBI JENUVJIJJJIP oy Aproads SJos UOTUId put 193 ZUN JOYIULIOYe IMOS sone IST UTe II0 ye ISULUI ABU uonisod oguejy SIU SUISN ore NOA PY Onea IRIS y UO ATUO spuodop uonisod SULT PNUIIJJIP JUL 79UO PJO MoA 0 JI JIE UO ABU NOX 3Od1IOD ST JI yey AINSUS 0 9J ISUEJJ 0 JOPJNOUS Suligog uonisod oguejy eENUSIAIJIP IQ ID 7 JINJILJNULUL JO ILQA JU uo Surpuodap sjunoo JUNAS JUVDIJJJIP JALU SJOPOUI SWOS VIS OPIS JETJUJJAJJIP JU UJIM SIPU LYS AXL InoA yey oImsug I pdyIoY aq 0 PIJU SUINI 7 OM SULMOJJOJ JU TENUJJIJJIP2. NOTE on page 2 for oil and additive requirements 7 Pi 9 ae INSTRUCTIONS Raise and support vehicle Remove wheels and brake drums or brake rotors Drain lubricant from carrier and remove cover Remove axle shafts from housing A C clip axles 1 Remove pinion shaft lock screw and pinion shaft 2 Push flanged end of axle shaft toward the center of the housing and remove the C clip from the button end of the axle shaft Repeat for other axle shaft 3 Remove axle shafts from housing Be careful not to damage the oil seals B Non C clip axles 1 Remove axle shaft bearing retaining plate nuts and remove the retaining plate 2 Use a slide hammer to remove the axle shafts Be careful not to damage the oil seals Note Some axles use shims or adjuster nuts to set the axle shaft end play Refer to the vehicle service manual for the proper removal and installation procedures for the axle shafts For removable carriers disconnect the drive shaft from the pinion yoke and remove the third member from the axle housing Prior to further disassembly measure and record the ring and pinion backlash Mount an indicator as shown in Figure 1 Hold the drive pinion stationary and rotate the ring gear in both directions to measure the amount of backlash or free play Check the backlash at three to four points around the ring gear and record for later use Mark bearing caps R and L to make sure that they
3. Program1 In order to qualify the unit manufactured date code must be less than 4 years old OR one must submit the original dated receipt of purchase The date of purchase must be within the last 4 years The date code is stamped on the differential case and will look as such 018 A9 20 130 or just A9 20 130 the first 3 digits identify the part number In this example 018 542018 the A9 identifies the month and year A January and 9 1999 the 20 represents the 20 day of the month disregard the 130 Hence this unit was manufactured on January 20 1999 and would be applicable for the replacement exchange program until January 20 2003 OR 4 years from the original purchase date The original dated receipt should only be submitted if the manufactured date code exceeds 4 years but the purchase date is less than 4 years If the manufactured date code is less than 4 years the original dated receipt is not needed to validate the exchange See the back for additional date code explanation 2 Contact your distributor point of purchase or Auburn Gear at 260 925 3200 x 328 or x 310 to get your Replacement Exchange Number RE Do not return your unit without getting this number In fact units returned without RE identification will be returned to sender 3 Fill out the Replacement Exchange Paperwork below Attach the address label to the outside of the box and indicate RE as provided by the distributor or Auburn Gear In addition place this form
4. JU 0 UO SSULL9Q JU SUISSJJd pue eog SULI JU SUTJJEJSUT 2J0JIJ ALON NOLLVOTIddV INVLYOdNI PINION SHAFT MODIFICATION Certain C clip axle applications with high gear ratios will require pinion shaft modification due to the thickness of the ring gear The thick ring gear will prohibit the pinion shaft from being removed making C clip installation impossible Use the following proceedure to modify the pinion shaft 1 Modification to be 90 to the pinion shaft lock screw hole as shown It is recommended that this be accomplished through grinding 2 Remove sharp edge from modified section by buffing 3 Pinion shaft should not be re hardened after modification Reinstall the pinion shaft prior to installing the ring gear With the ring gear installed rotate the pinion shaft so that the ground flat is parrallel to the ring gear face Pull the pinion shaft outward as far as possible Install an axle shaft and check that the end of the axle will pass the end of the pinion shaft An alternate solution is to index the ring gear on the differential until a tooth space is directly in line with the pinion shaft In many cases this will allow the pinion shaft to be removed without modification L ji L 2 0 10 Lock screw hole Ground surface _ CAUTION During installation of the axle shaft and C washer care should be taken as not to pry against or on the spring retainer plates This may
5. inside the box in a ziplock style or plastic bag along with the unit you are requesting to be replaced See the price for replacement on the back side of this form Note a distributor may charge an additional handling fee for administration of this program Also the distributor may have a unit in stock which will minimize the time required to get the new replacement unit In addition do not send the differential back with the bearings and or ring gear installed Auburn Gear will not be held responsible for product that has these components installed in fact they will be scrapped Date Code Stamped Here 018 A9 20 130 or fo 018 A20 06 IMPORTANT HOLD ONTO THIS DOCUMENT AND YOUR ORIGINAL RECEIPT FOR YOUR POSSIBLE FUTURE USE Replacement Exchange Number RE Place of Purchase Distributor Name Name Address City State Zip Telephone ____ Email address Note Ship to address as designated above must be the same as the bill to address if different please send a money order Place this form on inside of box with unit If original date of receipt is required for qualification please send it with this form Attn D REX Program RE 400 East Auburn Drive Auburn IN 46706 3499 USA 20
6. 7 38 39 40 Rotate the differential case several revolutions to seat the bearings Check the backlash as described in Step 6 Compare the backlash reading to the original reading taken in Step 6 and adjust as needed To increase backlash remove shim thickness from the ring gear side and add an equal amount of shim thickness to the opposite side To decrease backlash add shim thickness to the ring gear side and remove an equal amount of shim thickness from the opposite side Note approximately 001 of shim equals 001 of backlash Once the correct backlash reading has been established add 004 of shim thickness to both shim packs to preload the differential bearings It will be necessary to drive the shims into position Do not hit the bearing cups Itis advantageous to use a Case Spreader to install the differential Torque the bearing cap bolts to the proper value and rotate the differential case several revolutions to seat the bearings Recheck the backlash and correct if necessary Skip to Step 47 Place the differential assembly with ring gear and bearing cups into the differential carrier Apply a light coat of axle oil to the bearings and adjuster nut threads Install the bearing caps in their original position and hand tighten the bearing cap bolts Install the adjuster nuts unless still in the differential housing being careful not to cross thread the adjuster nuts causing thread damage W
7. acturer to the ultimate user of the product The manufacturer disclaims all other express warranties and all implied warranties including the implied warranties of merchantability and fitness for a particular purpose EXCLUSIVE REMEDY In the event of a breach of this warranty you shall return the product to the seller within thirty 30 days after the expiration of the limited warranty period along with your proof of purchase and explanation of the defect Seller or Manufacturer may investigate the claim of defect and in the event of a defect in the product shall at their election either repair the defective product replace the defective product with a new product or refund the purchase price These remedies are your sole and exclusive remedies in the event of a breach of warranty LIMITATION OF LIABILITY FOR DAMAGES In no event shall Manufacturer be liable for consequential special indirect or exemplary damages whether based upon tort contract warranty negligence strict liability or other legal theory Manufacturer s liability shall be limited to direct damages EXCEPTIONS TO LIMITED WARRANTY AND REMEDY This limited warranty and remedy gives you specific legal rights You may have other statutory rights in states that do not allow the limitation on or exclusion of certain warranties or remedies 18 D REX Program Differential Replacement EXchange Program Qualifications for the D REX Differential Replacement EXchange
8. cause damage to the spring retainer SPRING RETAINER SPECIAL NOTES Ford 8 applications require the use of the following carrier bearings LM 102949 Bearing Cone LM 102910 Bearing Cup Same bearings used in certain Ford 9 applications Ford 8 amp Ford 9 applications require the use of ring gear bolts from an open type differential Ford Part Number D802 4216 B Ford limited slip type bolts are too long Be sure to torque the pinion shaft lock screw to 20 25 lb ft The lock screw is not torqued prior to shipment on most models Chrysler 8 3 4 applications require the use of the following carrier bearings Stock bearing for 1969 73 applications LM 104949 Bearing Cone LM 104912 Bearing Cup Ford 7 5 applications require special C washers which are supplied with the differential Some AMC 20 Dana 44 and Chrysler 8 3 4 applications require the use of an axle spacer which is included with these units Some applications use a Tone Wheel for the Anti lock braking system In most instances this Tone Wheel is fitted to the outer diameter of the ring gear flange Remove the Tone Wheel from the original differential and install onto the new differential Refer to vehicle service manual for detailed removal and installation procedures CAUTION Be careful not to damage Tone Wheel teeth during removal and installation NOTE GM 7 5 8 applications use two 2 different Tone Wheels depen
9. d tighten it one When the proper backlash has been established install the adjuster nut locks Install third member into axle housing using a new gasket or silicone sealer and tighten nuts Reinstall drive shaft Skip to Step 47 For Chrvsler 8 1 4 and 9 1 4 applications using tool C 4164 adjust the position of the differential until the proper backlash reading has been established Refer to Step 6 for the backlash checking procedure and original backlash reading Alternatelv tighten each adjuster nut and rotate the differential case several revolutions to seat the bearings Being careful not to change the backlash repeat until each adjuster nut has been tightened to 70 Ib ft Recheck backlash and correct if necessarv Install adjuster nut locks Install axle shafts into housing being careful not to damage the oil seals A C clip axles 1 Remove pinion shaft lock screw and pinion shaft 2 Push flanged end of axle shaft toward the center of the housing and install the C clip onto the button end of the axle shaft Pull axle shaft outward so the shaft and washer seat in the counterbore of the side gear Repeat for other axle shaft 3 Install pinion shaft through the case and pinions aligning the hole in the shaft with the lock screw hole Install lock screw and torque to 20 25 Ib ft B Non C clip axles 1 Install axle shaft bearing retaining plate and nuts Tighten nuts to proper torque 16 Note Som
10. ding on the differential case series 3 08 1 amp down gear ratios Series 2 case 3 23 1 amp up gear ratios Series 3 5 Grind Here _ i La 1 00 LL Chrysler 8 1 4 applications require modification to the axle housing as shown to provide clearance for the differential case Clean housing after grinding LIMITED SLIP OPERATION Limited slip differentials are designed to transfer torque to the high traction wheel This is accomplished through a torque sensing clutch arrangement with preload springs During turning maneuvers the clutches are forced to slip allowing the wheels to rotate at different speeds The differential is a fully automatic torque sensing design Torque is instantly routed to the wheel with traction In some extreme situations the low traction wheel may begin to spin It should be understood that spinning the low traction wheel faster does not engage the differential In these situations slight application of the emergency brake will increase the torque transferred to the high traction wheel 6 INTRODUCTION There are two 2 items of concern when installing a differential Ring and Pinion Backlash Differential Carrier Bearing Preload These items are typically adjusted by means of shims or threaded adjusters The shims or adjusters will determine the position of the ring gear which determines the backlash of the ring and pinion set When installing a different
11. e axles use shims or adjuster nuts to set the axle shaft end play Refer to the vehicle service manual for the proper removal and installation procedures for the axle shafts 48 Using a new gasket or silicone sealant install axle cover and tighten bolts 49 Install brake drums or rotors 50 Install wheels 51 With the vehicle level remove the fill plug and fill housing to the proper level with the lubricant and additive described on page 2 52 Lower vehicle and test operation of axle FOR YOUR RECORDS Differential Part Number Purchased From Phone No Date Installed Installed By Phone No Vehicle Mileage NOTES 17 AUBURN GEAR INC LIMITED SLIP DIFFERENTIAL LIMITED WARRANTY AND REMEDY LIMITED WARRANTY Auburn Gear Inc Manufacturer warrants that this product is free from defects in materials and workmanship for a period of one 1 year after purchase by the consumer or 12 000 miles of normal use by the consumer whichever is less provided that this product has been installed and maintained in accordance with the Manufacturer s instructions and has been used in regular automotive driving and not in any off road application and has been used with the proper lubricant and additive as specified in the installation instructions at all times and has not been subject to modification accident or misuse This limited warranty is the sole express warranty provided by manuf
12. ial the backlash should be set to the original backlash setting which was measured prior to disassembly To increase the backlash adjust the shim packs or threaded adjusters to move the ring gear further away from the drive pinion gear To decrease backlash move the ring gear closer to the drive pinion gear Bearing preload refers to the amount of interference press fit of the differential case and bearings into the carrier housing Adjust the bearing preload by adding or removing shim pack thickness or by tightening or loosening the threaded adjusters Too much bearing preload will cause premature bearing failure Insufficient bearing preload will allow the differential to walk in the housing causing damage to the ring and pinion set and other components These instructions are intended as an aid for the experienced automobile mechanic in properly installing the limited slip differential It is expected that the installer be equipped with the proper tools equipment and experience before attempting the installation It is necessary to have an extensive selection of shims or adjustable shim packs to properly install the differential Threaded adjuster applications do not require shims MAINTENANCE It is recommended that the axle lubricant be changed every 7500 miles or as required by your vehicle s service schedule Lubrication breakdown can lead to accelerated wear to all rear axle components See IMPORTANT LUBRICATION 1
13. ith the adjuster nuts installed and the bearings in position torque the bearing cap bolts to the proper torque value For Chrysler 8 1 4 amp 9 1 4 skip to Step 46 14 41 42 43 Figure 6 Loose the RH adjuster nut opposite the ring gear until it is away from the bearing cup Tighten the LH adjuster nut ring gear side until the ring gear is slightiv forced into the drive pinion zero backlash Rotate the differential several revolutions to ensure no binding is present Recheck RH adjuster nut to be sure that it is not against the RH bearing cup Use an appropriate tool to turn adjuster nuts Install indicator as shown in Figure 6 Tighten RH adjuster nut until a case spread of 008 012 is measured Rotate drive pinion several times in each direction to seat the bearings and to be sure that binding does not occur It may be necessary to readjust the case spread by tightening the RH adjuster nut Measure the backlash as done in Step 6 If necessary adjust the backlash until it matches the original reading taken in Step 6 Increase backlash by loosening the LH adjuster and tightening the RH adjuster the same amount Decrease backlash by loosening the RH adjuster nut and tightening 15 44 45 46 47 the LH adjuster nut the same amount When making adjustments alwavs make the final adjustment in the tightening direction For example if the adjuster need to be loosened one notch loosen it two notches an
14. necessary to 25 Install the ring gear while hot onto the differential It is create a slip fit of the differential into the differential advantageous to use pilot studs to align the ring gear to the housing A slip fit is the thickest shim pack that can be differential as shown in Figure 5 installed by hand with slight resistance It will be necessary to rotate the differential case after each shim thickness change to seat the bearings 26 27 28 29 Figure 5 Using new ring gear bolts alternately tighten each ring gear bolt to the proper torque 3 8 Bolts 50 Ib ft 7 16 Bolts 80 Ib ft 1 2 Bolts 100 Ib ft For adjuster nuts skip to Step 35 Select two shims of approximately equal size whose total thickness is equal to the shim pack thickness determined in step 21 Place the differential assembly with the ring gear bearing cups and shims into the differential housing Install bearing caps and bolts in their proper position and tighten bolts While tightening bearing cap bolts continuously rock the ring gear back and forth to confirm backlash If at any time the backlash becomes reduced to zero remove bearing caps and adjust the shim packs by removing 010 from the ring gear side and adding 010 to the opposite side Repeat as needed until both bearing caps can be torqued to the proper torque value and ring and pinion backlash is confirmed 13 30 31 32 33 34 35 36 3
15. the axle housing bearing cap and ring gear Inspect axle shaft bearing surface bearings and seals Replace if needed Inspect differential bearings and replace if needed Always replace both the cup and cone as a set from the same manufacturer 10 Figure 3 Figure 4 18 Thoroughly clean the differential bearing hubs and ring gear mounting flange prior to installation of the bearings and ring 22 Remove the differential from the differential housing gear Measure the combined thickness of the shims This total shim thickness is what is needed for installing the 19 Install the differential bearing cones onto the bearing hubs differential prior te adding preload ta the bearinas of the differential case using the proper installation tool See Figure 4 23 Heat the ring gear and anti lock tone wheel if applicable with a heat lamp or by submersing in hot water Do not exceed 300 F Do not use a torch Note Many Dana applications use shims between the bearing cone and the differential case bearing hub shoulder The bearing cones must be removed to make adjustments to the shim pack thickness 24 Install anti lock tone wheel if applicable while hot onto the 20 For adjuster nuts skip to Step 23 outside diameter of the differential ring gear flange as stated l l ud in the vehicle service manual 21 Install differential with the bearing cups and shims into the differential housing Adjust the shim pack as
16. will be reassembled in their original position 8 10 11 12 Figure 1 If equipped with adjuster nuts remove adjuster nut locks and loosen adjuster nuts Chrysler tool C 4164 Ford tool T70P4067 A Remove bearing cap bolts and bearing caps Remove differential case It may be necessary to use a pry bar as shown in Figure 2 Exercise caution when prying on the carrier so that the gasket sealing surface is not damaged Place shims adjuster nuts and bearing cups with their respective bearing cap Note Adjuster nuts will stay in the housing in some axles Remove and discard the ring gear bolts With a non metallic hammer or brass drift punch drive the ring gear loose from the differential case pilot and remove Remove anti lock brake tone wheel if applicable Consult vehicle service manual for proper procedure 9 13 14 15 16 17 H dest le ee Figure 2 Remove differential bearing cones from the differential using the proper bearing puller and adapter See Figure 3 Clean all parts in a suitable cleaning solvent and dry thoroughly Clean axle housing by pushing a clean rag through the axle tube with a wooden rod Push the rag from the end of the axle tube to the center of the axle housing Wipe down the inside of the housing with a clean rag CAUTION Do not spin dry the bearings with compressed air Serious injury may result Remove any burrs from all machined surfaces in
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