Diff lock retrofit

1
I think there has been some confusion in naming of components.  The gearcases are the housing and I am fairly sure there is no difference in strength between locking and non locking or 2WD versions except the locking one has a boss for the shift fork to exit the case through.  I have one of these and holding it next to a 2WD one there is no visible difference in strength or thickness. (differential case half only).
The differential carrier is the rotating part that the crown wheel is bolted to and houses the spider gears.  There are 4 spider versions
 and 2 spider versions in the non- difflock carriers and some of these 4 spider versions have been found in 2WD gearboxes but if you buy a difflock, the carrier will be a 4 spider version anyway to handle the extra load imposed by the locked diff.  Spider gears are integral with the carrier; you can't change a 2 spider carrier to a 4 spider. 
If you want a four spider diff for its extra strength to replace a two spider diff without a difflock and you can't find a VW one Albins have one known as a super diff.  It uses the same spider gears and is made from a chrome moly billet.  I used one of these until I found my difflock. If you want to replace your standard diff with a difflock you just need to buy the difflock carrier, shift fork and gearcase half with shifter boss.  You will then also need to source the actuator and associated parts.  You will then have a gearbox equal in strength to a factory difflock equipped gearbox because it is the same. 
 
Neil.
 

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2
Thanks Neil -a good description of what is required for move to a diff-lock

If this is of help, someone posted some pics of the components some time back here:

http://groups.yahoo.com/group/syncrolist/photos/album/674865372/pic/list?mode=tn&order=ordinal&start=1&dir=asc

(I think they were trying to identify the parts, so descriptions not helpful)

Regards
Mark.

On Wed, Oct 7, 2009 at 12:59 PM, neil smith <jackthebearau@yahoo.com> wrote:

I think there has been some confusion in naming of components. The gearcases are the housing and I am fairly sure there is no difference in strength between locking and non locking or 2WD versions except the locking one has a boss for the shift fork to exit the case through. I have one of these and holding it next to a 2WD one there is no visible difference in strength or thickness. (differential case half only).
The differential carrier is the rotating part that the crown wheel is bolted to and houses the spider gears. There are 4 spider versions
and 2 spider versions in the non- difflock carriers and some of these 4 spider versions have been found in 2WD gearboxes but if you buy a difflock, the carrier will be a 4 spider version anyway to handle the extra load imposed by the locked diff. Spider gears are integral with the carrier; you can't change a 2 spider carrier to a 4 spider.
If you want a four spider diff for its extra strength to replace a two spider diff without a difflock and you can't find a VW one Albins have one known as a super diff. It uses the same spider gears and is made from a chrome moly billet. I used one of these until I found my difflock. If you want to replace your standard diff with a difflock you just need to buy the difflock carrier, shift fork and gearcase half with shifter boss. You will then also need to source the actuator and associated parts. You will then have a gearbox equal in strength to a factory difflock equipped gearbox because it is the same.
Neil.

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3

Neil,

 

Good summary, and thank you.

 

To try to lessen confusion for other members, the gears that you are referring to as ‘spider’ gears are also known as ‘side’ gears.  In terms of common usage, both are correct. 

 

Les

 

From: Syncro_T3_Australia@yahoogroups.com [mailto:Syncro_T3_Australia@yahoogroups.com] On Behalf Of neil smith
Sent: 07 October 2009 12:59
To: Syncro_T3_Australia@yahoogroups.com
Subject: [Syncro_T3_Australia] Diff lock retrofit

 

 

I think there has been some confusion in naming of components.  The gearcases are the housing and I am fairly sure there is no difference in strength between locking and non locking or 2WD versions except the locking one has a boss for the shift fork to exit the case through.  I have one of these and holding it next to a 2WD one there is no visible difference in strength or thickness. (differential case half only).

The differential carrier is the rotating part that the crown wheel is bolted to and houses the spider gears.  There are 4 spider versions
 and 2 spider versions in the non- difflock carriers and some of these 4 spider versions have been found in 2WD gearboxes but if you buy a difflock, the carrier will be a 4 spider version anyway to handle the extra load imposed by the locked diff.  Spider gears are integral with the carrier; you can't change a 2 spider carrier to a 4 spider. 

If you want a four spider diff for its extra strength to replace a two spider diff without a difflock and you can't find a VW one Albins have one known as a super diff.  It uses the same spider gears and is made from a chrome moly billet.  I used one of these until I found my difflock. If you want to replace your standard diff with a difflock you just need to buy the difflock carrier, shift fork and gearcase half with shifter boss.  You will then also need to source the actuator and associated parts.  You will then have a gearbox equal in strength to a factory difflock equipped gearbox because it is the same. 

 

Neil.