Monday, January 7, 2013

TEN Series Diff Build Tips

I just wanted to cover how to build a TEN series diff with the NEW TLR332001 HD Diff Housing, Integrated Insert: TEN.

Many have been asking for us to update the differentials for the TEN series vehicle such as the SCTE and after much work getting them right, the new TLR332001 HD Diff cases are finally on the market.  No more gluing inserts in place or tiny shims to deal with as we fixed it all.  Here is a list of the updated features:

-Integrated metal inserts – The metal inserts where the outdrives go through are now integrated into the plastic so there is less wobble and longer life with leak free performance.

-Thicker new material main gasket – The main blue gasket is being made out of new material and is much thicker to provide for more crush and a great seal.

 -Updated tolerances – We updated the tolerances so that the 4 tiny washers are no longer needed that go between the metal block and the planetary gears as well as ensuring the building of a perfectly smooth diff with each new build.

Now, let’s move on to building one of these.  The first thing is that you either want to start with new parts or make sure your existing parts are all nice and clean.  There is a great video that is posted by Adam Drake on building an 8th scale diff and you can always check that out.  The one word of caution is that on our 8th scale diff, we remove the washer that goes behind the pin on the outdrive BUT on the TEN series, you want to run that washer.

Now that everything is clean and/or new and ready to go, the first thing I do is to use some black grease to fill the grease pocket in the outdrive.  It is the line on the end of the outdrive that is inserted into the diff case.

Insert the now greased outdrive into the diff case and from the inside place the o-ring, washer, and pin in place.  Do this for both the diff cup and the diff cover. 

You will find 2 larger and 4 smaller differential bevel gears in a set of gears for the TEN series diffs.  Now place one of the larger of the two differential bevel gears in the diff cup side.

Take a notched diff pin and place on it a square, one of the smaller differential bevel gears facing inward, one facing in the opposite direction, and one more square.  Do this two times.  Place these in the diff cup making sure the notches in the pins line up with one another and the smaller diff gears are all the way against the larger bevel gear on the bottom.

Now, using the diff oil of your choice, squeeze oil in until it is about halfway coating the smaller diff bevel gears.  Place a finger against the center of the pins and spin the diff a couple times back and forth using the outdrive that is in the bottom of the diff cup.

Squeeze more diff oil into the diff cup until it is about 3mm from the top and place the other larger diff bevel gear into the diff cup.  Allow it to settle for a couple minutes at this point.

Take a finger and holding it against the face, wipe off the oil that is over the top of the diff cup.

Now take the diff cover side and place the blue gasket in place making sure to key it in place properly lining up the screw holes.

Flip it onto the diff cup lining up the diff screw holes as well as the pin and outdrive into the larger bevel gear.  The diff cover and diff cup should be flat together at this point.

Place the appropriate gear in place on the diff cover and insert the 4 diff screws. 

Put the bearings in place and put some grease on the ring gear if it’s a front or rear diff and you are good to go.  I hope you enjoy the new diff cases as much as I do!

Hope you enjoy the new goodies!