The ULTIMATE diff

To get a smooth diff I strip the diff right down and clean every part of it with motor spray and then dry them off with tissue and put the varoius parts in to pots i.e. diff balls in one, thrust balls in another then and trust plates, diff plates, diff screw, ball races and locking nut, spring and washer in another. I them take the pully and scrub it with a nail brush over the sink with hot water untill it it is totaly free from grit and grime.

I use associated stealth lube as its the best and was recomended to me by both Mark Stiles and Andy Moore. I put the diff lube in every hole in the pully making sure that there are no places that i can see through the holes and then place the diff balls in to the holes and put the ball races through the hole on the pully then place it to the side.

I then take a sheet of 600 grit wet and dry paper and sand both the diff plates and thrust plates on the scored side (the side with the ring around it) until the scoring has gone and the plates are smooth. I place the plates in the diff ball pot now as its empty and wash them with motor spray and then dry them and put to one side. I place some diff lube around the top edge of the diff halves and attach the diff plates to them sanded side up which secures them nicely and place some lube on the sanded side.

Then I hold the diff screw by the thread and place the first thrust washer over the thread sanded side up. Once its on the thread i use associated stealth grease as its in a tube and easier to use and put some grease all around the plate and pick up one thrust ball at a time and place them on the plate into the grease which holds them securely. I place the second thrust plate sanded side down over the diff screw which also attaches to the grease and thrust balls.

Finally at this point place the diff spring over the thread and then the spacing washer. Now the thrust race is complete. Hold the longer diff half horizontally and thread the thrust race that you have just built through the hole in the diff half and then hold it verticly making sure that you hold the right end so the trust race doesnt fall out and place it onto the pully. Pick up the short diff half and place it on the other side of the pulley, put the locking nut in place and tightern the diff screw gently untill the screw starts to feel tight.

Put the diff back in the car and tighten the diff untill you can only just move the diff, you check this by turning the left wheel with your left hand while you hold the the the right wheel with your right hand at the same time holding the spur with your index finger. You should only just be able to move the left hand wheel with quite a bit of force once tighterned. When this is comlete check the smoothness and if you have followed the insructions it should be as smooth as a babys bum.

Good luck fellas

thanx for that scotty I try to buy one of that diff Lube cos diff Lube makes difference other than I use the same method but cigarette lighter fuel cleans better than motor spray a bit stronger makes difference on diff pulleys you know the holes that balls sits in are the hardest to clean...
thanx a lot
Ali

Hey ali thats great but if you use ceramic diff balls the lighter fluid is too abrasive and will break the diff balls down so if you do change to ceramics i advise motor spray as it is not so harsh. Take care fella

I call that as a good tip
thanx scotty

motor spray is very good for cleaning everything as you know it wont damage the plastics. The best way to clean pulley gear holes is with tissue, just twist it then poke it through the holes, takes a bit of time but works the best.