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ZF LSD
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vwracerdave
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PostPosted: Tue May 13, 2008 5:31 am    Post subject: ZF LSD Reply with quote

I just got a ZF limited slip. Is there any where I can find a diagram or instructions on how to rebuild it. I don't want to take it apart untill I know what is inside.
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Type 5 Joe
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PostPosted: Tue May 13, 2008 5:47 am    Post subject: Reply with quote

There was a thread on the STF about this topic a little while ago....

No diagram, but they are pretty basic. I guess the clutches last a long time as long as they are not run dry. The thrust plates wear.... You will have to make some if needed.
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Glenn Premium Member
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PostPosted: Tue May 13, 2008 5:49 am    Post subject: Reply with quote

Bruce should be along soon.
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Stripped66
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PostPosted: Tue May 13, 2008 8:04 am    Post subject: Reply with quote

Glenn wrote:
Bruce should be along soon.


And if he offer's you $20 for that worn out POS, don't sell...I'll offer $40, AND pay shipping Very Happy
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Bodacious wrote:
Why not just make a custom set of wires with a Y splice in them. Then you could just run one distributor.

I don't think electrickery works that way
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gonebuggy
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PostPosted: Tue May 13, 2008 11:30 am    Post subject: Reply with quote

Bruce and I are working together at the moment to make up a batch of replacement thrust washers, better then OG!

Take your apart and survey the damage

Alex
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gears
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PostPosted: Tue May 13, 2008 12:28 pm    Post subject: Reply with quote

OE tabbed thrust washers are available for $18 each, although there's no real reason that they can't be plain (rotating).
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gonebuggy
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PostPosted: Tue May 13, 2008 1:51 pm    Post subject: Reply with quote

gears wrote:
OE tabbed thrust washers are available for $18 each, although there's no real reason that they can't be plain (rotating).


Where are they available? And yes there is a reason they have to be tabbed...

If they spin it wont be long before they start eating away at the diff body as i found out with mine when they sheared the tabs off!

Alex
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gears
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PostPosted: Tue May 13, 2008 2:38 pm    Post subject: Reply with quote

ZF went to a non-tabbed thrust washer in all their later diffs without changing body material, so a hardened and precision ground thrust washer isn't going to cause problems. The torn tab and/or lubrication issues is likely what damaged your body.

GT Gears @ (530) 878-4499 $18 ea 42.00mm OD x 31.15 ID x 1.8 thick
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vwracerdave
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PostPosted: Tue May 13, 2008 4:27 pm    Post subject: Reply with quote

Got it apart. Got one broken disc???. Everything else looked fine. No uneven wear. All parts looked OK and even thickness all the way around, but I've never seen one tore apart before.

What part is this and anybody know where I can get another one?

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Last edited by vwracerdave on Tue May 13, 2008 4:29 pm; edited 1 time in total
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Glenn Premium Member
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PostPosted: Tue May 13, 2008 4:29 pm    Post subject: Reply with quote

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gears
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PostPosted: Tue May 13, 2008 4:53 pm    Post subject: Reply with quote

What thickness ?
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vwracerdave
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PostPosted: Tue May 13, 2008 6:37 pm    Post subject: Reply with quote

The broken piece is .077" thick and very smooth on both sides.
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gears
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PostPosted: Tue May 13, 2008 6:55 pm    Post subject: Reply with quote

Is this one of the plain plates (totally flat), or is this an early style Belleville washer (curved, outermost part in either end of the stack)? Note: Most ZFs utilize round Belleville washers, while some early ZFs have Belleville's that are shaped like the plain plates ... I suspect that this is one of your two Bellevilles.
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Banzai KG
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PostPosted: Tue May 13, 2008 6:56 pm    Post subject: Reply with quote

This is listed in the Technical Manuals link:
6/1966 - Limited Slip Differential for Types 1&2 and 2/1968 - Limited Slip Differential for Types 1&2 - http://www.thesamba.com/vw/archives/manuals/techbulletins/h1.php
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vwracerdave
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PostPosted: Tue May 13, 2008 7:09 pm    Post subject: Reply with quote

The broken piece is totally flat.

It is for a IRS type I
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gears
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PostPosted: Tue May 13, 2008 10:45 pm    Post subject: Reply with quote

pm me with your address, and we'll get one to you ...
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Bruce
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PostPosted: Wed May 14, 2008 12:21 am    Post subject: Reply with quote

Careful Paul, Beetle discs are smaller than the stock P discs.
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vwracerdave
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PostPosted: Wed May 14, 2008 4:49 am    Post subject: Reply with quote

The OD of the circular part (not counting the tabs) is 76mm or 2.985"
The ID is 43mm or 1.690"
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gears
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PostPosted: Wed May 14, 2008 6:52 am    Post subject: Reply with quote

These are the same as early 904 ZF, which I'm having made right now ... so I don't have any in stock presently. So those frictions I sent you are too big to be of any use, Bruce ?
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73notch
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PostPosted: Wed May 14, 2008 10:56 am    Post subject: Reply with quote

Are the ZF units a Viscious type or a clutch pack type LSD? It seems hard to believe a clutch type would last this long.
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