[Highway-Star]

Ok there are some intelligent sorts do hang around here; so I am looking for people who can find any likely issues with an idea.

A few people on here will know about some mix and match differentials that are being played with. For the people who do know, I am asking here to get critical analysis from as many people as I can. Application is somewhat irrelevant for now (will just clutter up this post), I will explain what needs to be known below.

To make this mix and match diff work, some spacing has to be done. The spacing has to be done to make it so the differential's lash can be set to a sensible parameter. Without some spacing the diff will have extremely excessive lash. I think the best solution is to space the crown wheel from the carrier a small amount. I bodged up a "test" diff (bench examination use only) using some packing. 1.5mm of packing was insufficient, 3mm of packing was ample. So I am looking for something in this range (I will determine an exact number when I can).

The below picture shows my bodged up test diff:



Obviously the spacer would have to be machined with a tight tolerance for its inner diameter, outer diameter and particularly thickness. All the crown wheel bolt holes drilled also. 1040/1050 steel would be fine I would think.

Anyway, anyone who thinks this will cause issues please speak now, I want to hear it.

[joeblow]

You can't move the diff over by adjusting the side bearing nuts? you might just have enough room to do this and not have to make a spacer.

[Highway-Star]

joeblow wrote:

You can't move the diff over by adjusting the side bearing nuts? you might just have enough room to do this and not have to make a spacer.

No, can't get enough adjustment.

The below picture roughly shows the carrier over far enough to get appropriately zero lash:




Was also talk of spacing it over further using shims or spacers between either the adjuster and bearing, or the bearing and carrier. This solves the primary issue, but creates a few of its own issues. Non crown side adjuster nut protrudes and doesn't allow the centre into the housing for one. Also I have concerns that the squarer profile of an air locker for a carrier may fowl on the non crown side bearing cap due to being so far over (stock carrier doesn't fowl due to being so curved in shape).