L300 Lokka install: work in progress.

[Growlerbearnz]

Installing Lokka's (http://lokka.com/site/) front differential locker for Mitsubishi L300 ('87-'94). A work in progress, as you'll see. But first, a warning (thanks to ChuckBlack for pointing it out):

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The position of the differential ring gear in relation to the pinion gear is critical. As long as you put everything back the way it came apart, all the shims and bearings in the same place, neither should change. However, if you're changing the bearings, or you forgot which shim goes where, you'll need to read and follow the workshop manual to re-setup your differential correctly. It's a good idea to read the workshop manual first anyway. It's an even better idea to measure your backlash and check your tooth contact pattern *before* disassembly, so you can confirm that it's been reassembled properly. I got excited and neglected to measure first, but I also have a spare front axle. YMMV.
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Remove the front differential from the van. http://www.delica.ca/forum/viewtopic.php?f=6&t=17530

Take off the diff cover and extract the axle shaft. The workshop manual recommends a slide hammer, but you can also just lever here and tap it with a regular engineers hammer and it'll pop right out.

Remove Axle.jpg (74.77 KiB) Viewed 11625 times

This is where you're supposed to measure the backlash and, if you're paranoid, check the tooth contact pattern. I got excited and forgot to do either.

Mark the bearing caps so you can replace them in the same positions. Undo the bolts and remove the bearing caps, then lever the diff carrier out. **watch for the bearing races and shims- keep them on the side they came from so you can reassemble everything in the same place**

DiffOut.JPG (85.42 KiB) Viewed 11625 times

Shims.JPG (71.38 KiB) Viewed 11625 times

Mark the ring gear, then undo the bolts and remove the ring gear. **When reinstalling, you'll need to clean the threads with an M10 x 1.25 tap, and apply thread lock liquid- stud lock (the strongest) is what Mitsubishi specify.**

RingGear.JPG (64.88 KiB) Viewed 11625 times

Using a drift (or a dead drill bit, if you're a bit dodgy), remove the lock pin (it only comes out one way) and the cross pin. (It's a good idea to use soft jaws to protect the diff carrier and vice, but I didn't because reasons.)

LockPin.JPG (79.36 KiB) Viewed 11625 times

CrossPin.JPG (71.27 KiB) Viewed 11625 times

Rotate the side gears to remove them, then remove the axle gears. **keep the axle gear shims on their original sides**

GearShims.JPG (71.03 KiB) Viewed 11625 times

Now follow the instructions that came with your Lokka. On mine, they refer to the short axle gear going on the "long axle side, with no snap ring"- this is confusing, as both the long axle and short axle/CVs have a snap ring: Lokka have confirmed that the short axle gear goes on the long axle, and that they were trying to imply that the snap ring is optional.

The spacers that came with my Lokka had a sharp edge on the inside that interfered with the radius edge on the axle gears, making it impossible to install the cross pin. I've told Lokka about this, and they're looking into it.

SpacerSharp.jpg (48.27 KiB) Viewed 11625 times

SpacerDiagram.JPG (47.32 KiB) Viewed 11625 times

Spacerhigh.JPG (46 KiB) Viewed 11625 times

I ground off the sharp edge so the spacers would sit flat (a die grinder or Dremel will do), and it all went together properly.

SpacerGround.jpg (46.73 KiB) Viewed 11625 times

SpaccerFlat.jpg (47.96 KiB) Viewed 11625 times

Finally, installing the last cam gear can be tricky due to differences in the carrier casting- it appears this is common with any locker install. I had to grind a tiny bit off the carrier where it's marked:

GrindCarrier.jpg (67.52 KiB) Viewed 11625 times

This is still a work in progress: my side gear shims were super tight, and my clearances were too tight for the range the Lokka requires. My shims need to be 0.35mm thinner to bring everything into the middle of the range. The shims are very hard, so I'm trying to find a shim kit. Failing that I'll have them machined down by an engineer with a magnetic chuck.

-------------------- Useful part numbers (to suit 1991 L300 P25W SRPT1) -------------------
Diff side gear shim kit MB185519
Cross pin MB241909
Driveshaft seals MB290013
Diff side bearings MB092348
Cover gasket MB160579

[ChuckBlack]

I hope you pre measured your back lash before taking everything apart! Make sure the pinion and ring gear mesh exactly at the same stop. Teeth mesh with each other after some time, if installed differently you risk of having your diff blow out! Don't forget to set your bearing crush and pre load after!

[ChuckBlack]

And from the look of it you bearings look pretty worn out! Dull and discoloured races are signs of fatigue ! Do it since your right in it!

[ChuckBlack]

And use soft jaws on your vice seriously!

[Growlerbearnz]

Hi Chuck!

-Backlash: This diff doesn't have backlash/preload adjusters to worry about, it's all set with shims. As long as the shims don't get swapped around the backlash shouldn't* change. In any case, your hope is misplaced- I totally forgot to measure backlash before disassembly. I did measure on reassembly (within spec), and I did test the tooth contact pattern (also perfect). Preload felt unchanged too, but again, I didn't measure it. I've got a new set of bearings coming with the shim kit, so I'll probably have to set it up properly next time. But I'll try the "suck it and see" method first

-What, scratch up my lovely soft jaws on a big lump of rough cast iron? Just kidding... The magnetic soft jaws usually live on the vice, but the diff was a bit too big to fit with the soft jaws in place.

*Shouldn't. See "idiot proof", "Murphy's Law", "theory vs practice".

[ChuckBlack]

As long as you know what you're doing its all cool! I've seen all kinds of problems doing it this way... taking everything apart without taking measurements and after a few 100ks a towing is needed! Looks like you know what you're doing! Great pictures for everyone to see! Keep us updated!

[Growlerbearnz]

You have a good point though- I'll update my earlier posts to give a bit more information/warnings for people who aren't quite so familiar with diff work.

[Growlerbearnz]

My diff side gear shim kit finally arrived! Part number MB185519, about $60 (ouch).

20160519_101321.jpg (94.14 KiB) Viewed 11518 times

For reference, the pack has shim sizes; 0.80mm, 0.86, 0.90, 0.93, 1.00, 1.06, 1.10, 1.13, 1.16, 1.22, 1.27, 1.33mm.

Also in the package from Japan: new bearings, seals, and cross pin.

Of course it arrived just as I'd started renovating/rearranging the workshop, so the place is a shambles. Lokka installation will have to wait a bit longer.

[winelover]

Just got my lokka in. Great writeup, as usual! Would you mind posting the part #s for the bearings you got? I may as well order some in as well...

thanks in advance!

[Growlerbearnz]

Cross pin MB241909
Driveshaft seals MB290013
Diff side bearings MB092348

Just keep in mind that changing your bearings has potential to change the alignment between crownwheel and pinion. I've never had a problem, but your mileage may vary.

[winelover]

Thank you! That exact thought, and was going to measure before I pulled it all apart. Was it a PITA to get your bearings off the carrier?

[Growlerbearnz]

I use a 2-prong bearing/gear puller to remove the bearings, with the tips of the puller ground down to fit into the small space under the bearings, kind of like this:

W201 differential removal of axial shaft bearing races3.jpg (28.06 KiB) Viewed 11432 times

Damn! I grabbed that picture from Google as an example, but it's exactly the sort of dodgy setup I use. There's actually a proper tool available, which I really should buy someday:

images-1.jpg (8.51 KiB) Viewed 11432 times

W201_018 using bearing puller to remove ABS tooth in differential.jpg (41.72 KiB) Viewed 11432 times

[winelover]

Thank you, I was thinking something similar. May have to make a trip to harbor freight for a bearing puller. Any progress, have you tried it out yet?

happy trails

[Growlerbearnz]

About a month ago I decided to tidy the workshop, but it turned into a major renovation. Almost done...

[winelover]

Gees, well, you might as well post pics of that as well, because we could also use the inspiration/motivation...