adjusting new torsen diff in the rear (how i have done)

[Pirvu Eugen]

First remove the output flanges, then remove the diff cover and remove the old diff.
Remove the bearings and the crown wheel from the old diff and fit them back into the new one. Take care that the crown wheel is verry verry tight.

[UrS4boy]

Very grainy yet huge photo in the pdf. What is your point?

[Pirvu Eugen]

After mounting everithing on the new one, fit the diff housing in paralel position such way that the new diff crown wheel to be paralel with the ground. Fit an magnetic base with an clock indicator and fix him on one crown wheel holding screw and turn the diff in both directions to measure the play between wheel and pinion. This should be ~0.10 0.15mm at that measurment point. Tip : Clean all parts of oil before starting adjustment procedure, this will ensure that the play between gears will be audible too. If is no play, you have to add shims under the outer cage off the big bearing, if is to much you have to remove shims.

[Pirvu Eugen]

Sorry about the quality of the pictures and about that they are big, but i have no editing soft for pictures to make the smaller in size

[Pirvu Eugen]

It's an rough guide how i have put in my rear diff an V8 torsen one. If somebody is intrested, i am sure that you will understand what i have done.

[Pirvu Eugen]

After adjusting the pinions play is time to adjust the pretension of the bearings. I have done this by fiting the cover back and with a small hammer (like in the picture) in one side of the cover only until in the opposite side you have 0.10 mm distance measured with an feeler gauge. At the end that 0.10 mm represents 0.05 mm pretension. I have fix mine like this and there are no problems. If is to much distance then you have to remove some shims under the outer cage from the small bearing, iff is no distance then you have to add shims. When you have one side touching and the other site 0.10 mm then you can put some sealing paste and mount the diff cover back. Put the output flanges back and finish. Take care that the output flanges from the torsen are diferent that the normal ones.
Hope this helps!

[meep]

nice tutorial! Thnx

[Error404]

I need to do this on my diff as I have too much backlash after fitting the Torsen unit.

What Eugene posted isn't totally correct, or maybe I have misunderstood his posts above?

You cannot just add shims under one bearing race, you have to redistribute the shims between the two sides to adjust the backlash - this way you maintain the bearing preload which is set from the factory. Also the bearing preload needs to be adjusted before you set the backlash.
If you change a bearing or in our case we change the diff carrier then you need to reset the bearing preload. to do that you need to press out both outer bearing races and remove the shims behind them, then press the races back in and check axial play in the diff carrier between the bearings. Then insert shims behind the bearing races to the value of the axial play plus the the constant bearing preload which IIRC is 0.25mm. It is these shims under the bearings races that need to be redistributed to either side of the diff carrier to adjust the backlash at the crown wheel / pinion.