Jaguar Differential rebuild
 

Hi you all,
On my last rally I abused the car really hard, and on the last day I broke my differential.
It is a Salisbury 4HA unit with powerlock and 3.54 ratio.
I dissasebled it, to find several ring gear teeth broken. I ordered a Superior Ring and Pinion set.
I also replaced all bearings, because all those teeth bits in the oil were probably not especially good for the bearings. The bearing cup races were pitted, so changing them was the best I could do.
One problem was the flange adapter, since the original pinion gear had a 10 spline shaft, and all the pinion gears on the market have 26 spline. Since Dana/spicer does not manufacture the flange adapter any more I had one made locally, which cost more than the whole ring and gear and bearing kit.
The hardest part is to adjust the pinion gear depth in relation to the differential, and after getting myself a suitable and small enough magnetic base to hold the dial indicator I managed to get the adjustment right .I had to add a 0.25mm shim (and removed the same value from the front pinion bearing shim pack) Regarding the crush sleave, you only need it if you do not use shims. I prefer to shim. It is more work but once you get it its set. Could not find those damn crush sleaves anyway.
Unfortunately I am stuck now, because in the instruction on how to adjust the side bearing preload , there is talk about shims, which should be placed behind the bearing cups in the differential case ???.
But the differential case is open on both ends where the side bearing cups go, with no stop whatsoever to seat the bearing cup nor any shims against.
I suspect that the shimming is done installing the drive haft carriers and shimming those to give the correct preload and play for the differential unit.
In this case the bearing cups would seat against the drive shaft carrier
Has anyone done work on theses differentials and knows if this is so regarding the side preload and play?
http://www.clubcobra.com/photopost/d...ff_housing.jpg
http://www.clubcobra.com/photopost/d.../ring_gear.jpg
http://www.clubcobra.com/photopost/d...ium/flange.jpg

My rear looks like yours right now , although mine is a dana , I think the preload on the differential is the amount of shims (total left and right )on the carrier bearings , the cups are not shimmed on mine
The differential was sob to get out , and shims were on each side of the carrier (case) then the bearing, followed by the cone / cup .

Output shaft end float .001-.003"
Differential bearing preload .006-.010" shim allowance
Pinion bearing preload 8-12 lbs/in
Backlash as etched on drive gear min .004"

differential mesh pattern
 

The backlash and the bearing preload of the carrier is adjusted with the shims between the housing and the stub axle carrier.
The right side is for adjusting the the backlash, the left side adjusts the bearing preload.


http://www.clubcobra.com/photopost/data/500/Shims.jpg


After putting all back together I checked the mesh pattern, which looked e a little too much like top of tooth contact,
so I rearranged shims to take the pinion ou tof mesh and got the pattern on the pictures. Actually it did not change much.


http://www.clubcobra.com/photopost/d..._side_8mil.jpg
http://www.clubcobra.com/photopost/d..._side_8mil.jpg



Is this good enough ? Expert diff builder please advise.
Thanks