PLEASE bare with me, I want this to be thorough so i will be putting this together in parts and editing as I go.... EDIT, I think I may have it finished!
J
Undo bolts and remove top
Pull out passenger side axle gear, Notice the side up and groove is towards inside of diff for axle clip
This is what is underneath, two gears that the belleville washers are under
Remove the small gear inside on top of the washers to expose them. Note that at this time there is no bevel on the gear in my fingers. With it like it is, the axle will not slide in far enough to lock the clips.
The infamous Belleville washers. These shown are the New upgraded washers
Stick your finger in the hole...lol and pull out the stack. Note mine are )()().
remove the bottom little gear. Both top and bottom are the same size. ONLY ONE needs beveled.
remove the large gear that the smaller washer gears sat in
you are looking at the passenger side axle gear. It is not beveled and if you put a clipped axle inside there, it would not come out. That needs to be beveled to an angle.
go ahead and pull these spiral gears out and set them aside. removing them makes it easier to move the base when test fitting the axle
Pull out the passenger axle gear
This is where we will bevel a smooth angle. The goal is to angle the splines back so the axle clip will not hang on the strait edge of the splines.
we want it to look similar to this side, no idea why they wont do both sides but whatever...
order everything goes back in (DONT PUT BACK IN YET) starting bottom left then bottom right then left to right...
If you have not had your LSD prepped (i had turbosunleashed do mine and they did a great job!) now is the time to do it. clean up any excess casting flash, and if you have the tools, run a tap into the bolt holes to clean them up. If you dont have the tools, Turbosunleashed overs a service to overhaul it for you.
all of the parts lined up
Take a socket wrapped in tape and shove it into the center of the axle gear. Make sure you have it strait as possible. Place in a lathe or something that will spin true, drill will work also. Use a dremmel with an angled grinding stone and remove the edge to give a slope similar to the front side of the axle gear. Like so...
outside of passenger side axle already beveled by OBX.
our beveled pax axle gear
Drivers side axle gear is beveled on mine on both sides. the problem with the inside bevel is that the bevel is too sharp. The axle clip still gets stuck and will not come out. So take your dremmel and custom socket/tape tool and make the bevel more laid back than original. Yours may not have any angle to it at all. In that case, bevel it like you beveled the pax axle gear, no sweat. This is the outside that is fine. The next picture shows what to do to the inside.
Here I beveled the inside some more to allow the axle clips to slide on and off. Take your axle and test fit the bevel as you go. Any lip on the bottom of the splines will cause the axle clip to get stuck so bevel it all of the way down to the base for a smooth transition.
The Infamous belleville washers again.
PART 2
How the washers sit inside of the carrier gear
Bellevilles sit inside the two gears in the recessed area.
How they will sit inside the center of the LSD. Note the top halve has been beveled. This is because the bevel from OBX wasnt enough to allow the axle to seat all of the way. So I touched it up and now it does as you will see in later pictures.
Note the beveled on on the left and the untouched one on the right. Gauge how much needs to be beveled by placing the axle gear on the axle until the clip engages then place the washer gear that you beveled and make sure it sits flush against the axle gear. if it doesn't, bevel it out a touch more.
only bevel one, the other should remain untouched
This is the axle clip that holds the axle in. This is what we DONT want to get stuck inside the differential.
you can see our beveled edge that has a smooth transition with nothing for the clip to get hooked on.
Slide your gear on to test fit and check the bevel. Do this often, you dont want to have to try to pick it out with dental tools to compress the clip because you didnt make the bevel slope enough. What I did was ran it in backwards. Meaning I put the reccessed end in first, that way I know it wouldnt go forward if the edge was to sharp. So see how it is oriented in the picture below, turn the gear around so you are placeing the axle into your freshly beveled side. If it slides in with out hanging, congratulations! If it hangs, bevel some more and test fit again.
Once you get your bevel set correctly, and the above process works for both sides, slide your drivers side axle in correctly like pictured above. slide it on the axle until the clip clicks. It should look like this.
Now look at your two washer gears.
If you dont bevel the edge of the drivers side washer gear (both are the same size so just pick one to be the drivers side and bevel it) then you will see the 1/16th" gap. That gap is enough to not let the axle clip engage when the case halves are put together. see the gap
better picture of the gap
now align your beveled washer gear and test fit it
It should sit flush like so
PART 3
Ok, when you are satisfied with your beveling of your axle gears and your ONE drivers side washer gear (like I said just pick one) It's time to put it back together and test fit your axles.
Now if you removed your lower spiral gears place them back in their recesses with the holes in the center facing up. Also note in this picture the dowl pin standing strait up.
That pin aligns the case halves to this hole that is not machined for bolts
so next we will place our pax side axle gear into the lower case. make sure the recessed edge that we beveled is facing up. That is where the axle clip will engage.
Like so
Next place the large gear that the washer gears go into, into the lower case
place your UNBEVELED washer gear in with the recessed side up so your washers will sit in the middle.
stack your washers back in Mine re )()() with the ) on the drivers side.
Now take your beveled washer gear and place it on top of the washers, inside the bigger gear.
Place your upper spiral gears back into the case
Now place your drivers axle gear into the spiral gears with the recessed side down.
Now here is what I did to verify final axle fitment. I bolted the case together with medium pressure with 4 bolts, basically enough to hold it together. Then I placed the drivers side axle into the drivers side of the case.
Push the axle in until it clicks. If the axle bottoms out and the clip does not click then you need to bevel the washer gear more because you did not have it beveled enough for it to sit flush against the axle gear. If you get lucky and slide the axle in the case and the axle clip engages on the first shot congratulations! Ill drink a beer to that! It should look like this. It will have just a very slight touch of play not alot at all expecially compared to the passenger side.
Now if the passenger side engaged and you can remove the axle from the diff with only a reasonable amount of pressure, meaning the clip isnt getting stuck then test fit the passenger side. the passenger side should slide in and click with no problems. What we are looking for is that both axle clips engage, hold the axles in, and then the axles can be removed.
When you are satisfied with your axle fitment, take each bolt and put a dab of blue thread locker and torq each to 28ft.lbs. Let sit for the specified curing time for the thread locker and away you go!
I have a video that I made showing the axles locking in and pulling out. When I figure out how to load it on here I will share it with everyone else.
I hope this helps some people who were considering an OBX differential for their car. Good luck and as always If you don't feel comfortable working on your car for something like this talk to a pro, this is for information only and may or may not have every think you need, or warranty for the information contained.
Got any questions just give me a shout!
J
