- KAM Differentials

The KAM Differentials Ltd
LAND-ROVER Differential Lock
2012 Fitting Notes:
Rear D2: Watts linkage pivot arm bolt can foul the KAM diff cover special bolt required.
Range Rover 1995> P38 Watts linkage removal reuqiered Front & Rear
KAM
DIFFLOCK
Patents Pending
R Tracy 06
Defender 90 rear 1998>:Use Part No: KAM436 or 435 Shallow cover to miss rear fuel tank.
2A + 3 Series 88"
Rear Only. Will require 24 spline shafts + Hubs+Spacer+Bearing Adapters Part No: LR48IK
Note: All applications require standard 24 spline shafts
Versatile
Reliable
Military Spec. Design
Upgradeable to LSD
HD 4 Pinion Differential
DIFF
4 PIN
RATIO
DIFF
LSD
FUSED
HD SHAFTS
CV
HUB
kamdiffs.com
CAUTION - AS WITH ALL DIFF LOCKS...
DO NOT ENGAGE THIS SYSTEM ON METALLED OR
CONCRETE SURFACES.
Optional LSD
Optional HD Halfshafts
Optional CV Convertion
Optional Crown Wheel and Pinions
Optional Driving Member Hubs
"THE MOST VERSATILE TRACTION SYSTEM FOR YOUR VEHICLE"
FITTING INSTRUCTIONS
Ref: KAMDifflockerfittingV6 2012
& PARTS LIST
KAM
TM
www.kamdiffs.com
Introduction- Difflock System
Welcome !
Thank you for choosing the KAM Differentials Ltd
Diff Locking System. Please take the time to fully read
these instructions before commencing any work.
Background History
The new KAM Diffs locking system was developed at
the request of the military to produce a more cost
effective axle locker which would be easy to install on
the factory production line or to retro fit into existing
vehicles already in service. There are now over 5
thousand vehicles in active service with this system
fitted.
Overview
The system utilises a heavy duty solenoid mechanism
to operate the tried and tested sliding dog method of
locking the differential. This assembly can then be
neatly installed onto the axle casing by means of fitting
a steel mounting ring. A detachable cover then takes
the place of the fixed diff pan originally fitted.
A cable runs from the solenoid to the cab where an
illuminated rocker switch operates the Diff lock. An
IP68 rated gland ensures a water tight seal where the
cable enters the cover.
The solenoid itself is a dual coil type, electronically
controlled and protected by an integral solid state
commander module.
A short 45 amp burst of power ensures a positve
engagement and a constant 1 amp draw holds the
solenoid in a locked state until the driver turns the
switch off.
The solenoid operates a fork, which when operated
preloads a spring. The spring then forces the sliding
dog along the a newly pattented tube until it locks onto
the carrier l ocking boss. This method allows smooth
engagement of the dog gears.
As a failsafe, the system will always disengage.
Fitment
The system can be fitted to any of the Rover type
"banjo" axles as fitted on:Land Rover - Series II, SIII, 90, 110, Defender
(Non Salisbury type)
Range Rover - Classic all models up to '95 (pre P38A)
Discovery - All models up to TD5/500 series.
NOW AVAILABLE for 2004 onwards 110 & military
WOLF axles
System is also available with Limited Slip Differential
(LSD) as on optional extra, which allows the axle to
have Limited Slip with the benefit of Locking Overide.
Other Optional extra's and upgrades:
Extra heavy duty halfshafts (aerospace steel)
Heavy Duty Driving Member Hubs
Limited Slip 4 Pinion Differential (fully adjustable)
Flange Sealant (to ensure oil tightness of welds)
Installation
We hope we have made these fitting instructions as
clear as possible, but if you are in need of any further
assistance, please feel free to contact us via our
website www.kamdiffs.com
The fitting instructions have been tailored for a Rear
axle installation, although the basic instructions are the
same as for the front. (see notes below)
We have made every effort to ensure these Fitting
Instructions are correct and concise, We would
appreciate any feedback of mistakes or
improvements we can make, so we can amend for
future issues.
We wish you good luck with the installation and hope
it gives you many years of use.
Front Fitment
Installation to the Front Axle is similar to the Rear
axle in nearly all ways. The only real differences are :1) Cut out and Lock mechanism is on the Long shaft
side of axle.
2) The removal/refit of halfshafts (CV's and stub axle)
3) Steering rod
4) Anti roll bar (if fitted)
5) Brake Calipers (if fitted)
6) Steering damper (if fitted)
With this in mind, it may well be preferable to remove
the front axle for easier fitment.
Ensure that the cut out section is on the LONG side
of the axle !!
Note:
Before installing on the front axle, ensure that the
correct type of half shafts have been ordered:24/23 Spline - Range Rover / KAM CV Conversion
24/32 Spline - 200/300 Series Without KAM CV's
We thoroughly recommend that if the Diff Lock is used
for any heavy or competition work, then a KAM CV
conversion should be installed to allow the use of the
far superior 24 spline front halfshafts. Then not only
will the vehicle have stronger shafts, but also a
"managed" weak link in the form of replacable "fused"
stub shafts.
Caution
If fitting this diff lock to the front of your vehicle, it will
adversely effect the steering.
Note: When welding make sure there is good venterlation
to extracted the fumes. Make sure you have removed
all oil from the axle tube as this can catch fire.
Stage 1 - Axle preparation
1) Firstly drain oil from differential via drain plug.
Rear Axle
10) Remove the Mounting Ring and cut away the
marked area with angle grinder or gas torch etc.
Ensure the edges are deburred.
Ensure that cut out is on the SHORT side Rear and
LONG side on the front 110/130/90/D1/RRC/
P38 Ranger Rover Front Long side rear long side
Existing Diff Pan
2) Chock the front wheels, Jack up rear end of vehicle
and safely fit on axle stands.
3) Remove half shafts
4) Undo prop shaft and remove differential casing unit.
Warning Diff is heavy ! (25kg) We advise using a Jack
5) From the Diff aperture (hole), carefully plug up each
axle tube, to avoid debris from getting in the axle tubes
If possible use something that is not likely to catch fire.
A steel insert requires a hole drilling or cutting with a hole
saw of 19mm. The steel insert can then be welded or
bonded around it’s edge and the gland then screwing
home.
See Wiring gland “up date”
Cut 19mm hole
Page no 11
for steel insert
Make sure the plug material has been pushed far
enough up the tube !
11) Offer up the Mounting Plate as directed in 8)
A small tack on the inside of the ring is best to hold
ring in place. There are 4 indents marked on the inside
of the ring, use these also to aline then weld in this
position. Try to ensure that the Mounting Plate is held
flat and parallel against the axle. Do not over titen
any clamps that are used to bold the ring in place.
Welding fillet
Tack
6) Remove existing Diff
Pan (Cut with angle
grinder, gas torch, plasma
cutter etc) Cut off just
above where diff pan meets
diff casing.
7) With an angle grinder
clean up remaining
weld, leaving a raised
(approx 2mm) bead of
weld around the hole.
Degrease thoroughly
around area.
110 2004> P38 Short Nose Rear Diff only
This is fitted in the same way but the diff unit is a short
nose version and the axle casing has a 16mm round ring
fitted as standard between the pan and axle. Just remove
the Diff pan as the Rover long nose type. You will then
have to use the 16mm adapter plate to fill the gap on the
right hand side behind the mounting ring.
Longer fork
16mm adapter
Welding fillet
12) When satisfied that the Mounting Ring is tacked in
the correct position, slot in and weld the welding fillets
in place. These take up the space where the curvature
of the axle tube runs away from the mounting ring,
above and below where the solenoid will be mounted,
and also helps protect the mounting hole threads.
13) Next, run arrouned 70mm of weld at a time around
the Mounting Ring. Weld in stages in opsite positions
The bottom edge is the most critical for oil tightness,
so take particular care in this area. Remember, this is
also adding strength back into the axle, so make sure
a good strong, pentretrative weld is achieved.
V markers to
aline the ring
70mm Weld
8) Offer up Mounting Ring to axle casing in place of
the diff pan. There are two outer recessed V shaped cut
marks. Align the V with the existing horizontal weld
marks on the axle tube. Also, align the innercircular
edge of the Mounting Ring with the inner circular edge
of the hole in the axle casing. There are marks to help.
9) Then, with a marker pen or scribe etc. mark
out the area of the axle tube that is exposed
under the Mounting Ring.
70mm Weld
14 Clean out all debris from diff casing and axle tubes.
Stage 2 - Differential Assembly
1) In a clean environment, remove the differential
bearing caps, and withdraw the old differential assembly.
Stage 3 - Locking assembly
1) Install spring onto Sliding Dog.
2) Check Crown wheel, Pinion, pinion bearings for
good condition. Replace any worn parts. Check
APPENDIX 1 for bearing information.
3) Carefuly remove the Crown wheel from the old
differential assembly, also remove any spacers or shims
if used.
4) Install the crown wheel (and shims etc) onto the new
4 pinion Differential Assembly. Preferably use new 12.9
bolts.
5) Torque bolts up to the recommended manufacturers
setting (See APPENDIX 2 at rear of Instructions)
Crownwheel fitting instructions can be found on the
following website: www.kamdiffs.com
6) Check Diff carrier bearings for wear (replace if
necessary). Fit bearings onto new 4 pinion Differential
assembly and install back into Diff housing.
SEE APPENDIX 1 FOR IMPORTANT BEARING
INFORMATION BEFORE PROCEEDING.
Locker Only Quill Shaft Fitting
For applications with diff locker only the Quill shaft can
be pushed in until a snap ring holds the quill shaft in
place. When you fit the half shaft slowly rotate unit splines
line up.
RTC3095
Standard
Land Rover
Metric
Bearing
KAM306/52
KAM
Bearing
Suplied
7) Fit the new Bearing Adjuster to the Locking side of
the assembly and tighten as per manufacturers
speciification (this allows the sliding dog to fit through
the bearing adjuster). Ensure correct mating and back
lash of crownwheel and pinion, using engineers blue
as a final check. SEE APPENDIX 2 & 3
New adjuster locking plate
Later models have role pin
Do not punch pin below this piont
2) Slide the 2 large
washers onto sliding dog
3) Fit cirlclip onto sliding dog, securing the spring and
washers.
4) Re-install Diff Assembly into axle, remembering to
fit gasket.
5) Visually inspect locking tube and locking dog and
halfshaft splines for any burrs or dents. Test that the
sliding dog moves up and down freely on all splines.
Sliding Dog
Place in cases first
6) Place the Sliding Dog assembly into the axle tube
though the cut out hole. Push to the right. Then place
the locking tube in to the end of the carrier, slide tube
home to the left though the bearing and make sure that
the tube locks in to position on the wire clip Wire clip
is pre fitted inside the carrier.
Quill Locking tube
Removal
Holes
To remove the locking tube place a 4mm bar though
the two holes and tap lighly to the right.
7) Now, push the sliding dog onto the locking tube.
You can use the half shaft to push the sliding dog up
so you can get hold of the dog with your fingers. Prise
apart the washers and install the forked end of the
actuator fork between washers.
Quill Locking tube
C clip grove
New bearing adjuster
8) Install bearing cap with new adjuster locking plate
and use to lock off new adjuster ring.
9) Have a final check of assembled differential for
smoothness of operation.
Push quill locking tube in to the carrier up to this mark
8) Install half shafts. Fit drive member hubs and gaskets.
9) Using M6 X 16 Caphead bolt, (and lock washer)
locate Microswitch assembly onto the bottom Right
hole of Solenoid Mount, (switch
locates into a cut-out slot) ensure
actuator arm faces away from
the mount.
Use 2 more M6 X 16 capheads
with lock washers to firmly bolt
the solenoid mount in place.
14) Differential Locker. With both wheels securely jacked
off the ground, slowly turn one wheel; the other wheel
should turn in the opposite direction. Now, with the aid
of another person to turn the wheel do the above test
again, but this time before turning the wheel press the
solenoid inwards to the lock position. After the Sliding
Dog aligns and engages onto the Carrier Locking boss,
the other wheel will turn in the same direction.
15) Although the system is designed to work instantly
with minimal set up, it may be necessary to minutely
adjust the fitment of the Solenoid and Solenoid mount
bracket to achieve the smoothest operation of the
Sliding Dog. (This is because of variances in welding
and alignment of Mounting bracket etc.) Spacer washers
can be added behind solenoid bolts etc.
Stage 4 - Diff Cover & Wiring
10) Compress Solenoid (push in spring) and slot
Solenoid assembly into cut-out, with flange on the
LEFT HAND SIDE of the mounting bracket.
1) Feed one end of the Wiring cable through the Diff
axle casing wiring gland,
Use silacant sealer to ensure water proof
Stage 3 - Continued
Compress Spring
11) Bolt Solenoid in position with M6 X 16 bolts, anti vibration washers and flange nuts. Fit cable clamp on
lower bolt (see wiring - Stage 4)
12) Add a few drops of Loctite 243 to countersunk bolt
and attach Actuator Fork to solenoid.
13) If needed, bend the microswitch
mounting plate so that the
microswitch actuator arm will make
contact against fork, when sliding dog
is locked onto the diff assembly. The
actuator arm can also be bent to
perfect switch operation. Adjust until
a faint "click" is heard from the switch
when the sliding lock is put in the lock
position.
3) crimp on female terminals to all four of the wires.
4) Using a short offcut from the other end of the
cabling, make individual Yellow and Red wires 14cm
long, with Female connectors one end and Male the
other.
5) Connect the Red wire's Female end onto the
COM connector on the Microswtich (nearest to the
solenoid) and the Yellow Female to the NO terminal
(furthest from the solenoid) See Diagram below.
6) Cut off the Solenoid Wires to 14cm and attach
male terminals to them. Then route the solenoid
wires and the 2 short wires from microswitch
through the gap under the solenoid.
Bend switch plate
to ensure microswitch
lever makes contact
with Actuator Fork
when solenoid is
activated.
7) Wrap 2 x cable ties firmly around the Solenoid,
holding the Solenoid wires in place.
8) Connect the corresponding wires onto the main
cable, coming through the diff casing. I
L
3
24
E AL
IT SE
CT 'N
LOOCK
ALSO SEE WIRING DIAGRAM STAGE 5
Solenoid Assy viewed from below
Note: The Solenoid and Coil Commander can come in
2 types.
Type 1 Coil commander fixed to the solenoid
Type 2 Coil commander separate to the solenoid
Coil commander to be fitted on the outside of the axle
l
3m
Coil Commander
Solenoid
Type 1
Solenoid Mount
Cable tie
Top of Carrier Bearing cap
Microswitch Assy
If preferred, move onto Stage 5 to complete the wiring
and testing of solenoid, before fitting Diff Casing.
14) Gently pull cable through the cable gland until slight
resistance from the cable tie can be felt. Tighten up the
cable gland's top nut to ensure a water tight seal.
Apply silicon sealant for added reassurance.
15) Fit 20mm O-ring onto oil level sight glass thread. Fit
sight into lower hole of diff casing. Use silicon based
sealant if desired to ensure oil tightness.
16) Fill diff with EP80 -90 oil 2 liters No more
13) Fit oil plug.
R Tracy 06
Stage 4 - Continued
9) Put an M6 flat washer and a fews drops of Loctite
243 studlock on each of the 15 M6 X 18 caphead screws.
10) Then, put 2 or 3 of the screws, through the holes in
the Diff Case. Align the Gasket with the Diff Case, and
place the Gasket in place on the Diff case, over the
screws. (use gasket sealant if desired, although not
essential)
11) Offer up the Diff Case to the Gasket and Mounting
Ring and loosely do up the screws, keeping the Gasket
fully aligned all the way around.
12) Loosely install the remainding M6 X 18 screws and
washers.
13) When all screws are loosely in their holes, double
check that the Gasket is in place and finally tighten the
screws.
Diff cover M8 X 18
8 lb ft Do not over tighten
Stage 5 - Electrical connections
4) Cut a 22 X 41 mm (7/8 X 1 5/8") hole in a suitable
location, such as the dashboard or auxillary switch panel,
for the Operating Switch. Install Switch at preferred
location.
1) Run and attach the cable loom along the chassis,
feed through bulkhead into dashboard (or wherever
Operating Switch is to be fitted) Remember to leave
enough slack at the axle to allow for movement of axle.
5) When fully wired up and installed, re-fit the Fuse.
2) Connect the system as illustrated in the Wiring Diagram
below. The connections listed in the diagram correspond
to the actual terminals on the Main Switch, Relay and
Microswitch. Leave Fuse out of Fuse Holder until fully
installed.
6) With the vehicle still on axle stands, test the system
by operating the switch.
Note. As the differential is not turning, the Sliding Dog
may not immediately engage when the switch is operated.
Simply turn one of the wheels a little and the gears will
align and engage the lock. This will of course
automatically happen when the vehicle is in operation.
3) We recommend taking the +12 volt supply, direct
from the battery to the Fuse, using a length of the larger
(44/0.3) wire supplied (Do not use any lower rated wire
for this !) Use the other off-cuts of wire to connect the
relay to the switch etc.
7) Now, re-connect the prop shaft !
The installation is now complete and the vehicle can be
lowered down from the axle stands.
Tech Data
Fuse
Relay
- 35 A Blade type
- 12v 70A Heavy Duty
Mini make & break
Main Switch - Single Pole 15A 28V
Micro Switch - 240v 4A Cherry
Cable
- 2 X 44/0.3 + 14/0.3
PVC sheathed
We recommend to change the diff oil after 500 miles or
after 1st race if used in competition.
Types of micro switch
Some kits may come with one of two types of microswitch. One BLUE and the other WHITE.
These although look the same, need to be wired up
differently. The white micro-switch should be wired up as
per the instructions, however, if you have the blue microswitch, then the wiring needs to go to the terminals as
displayed below.
Wiring Diagram
Note: Cable wiring may change core colour
+12v
Fuse
30
85
Main Switch
Carling
9
Relay
WIRING FOR BLUE
MICRO-SWITCH
WIRING FOR WHITE
MICRO-SWITCH
86
87
10
3
2
7
8
Earth
4 core
sheathed cable
Grey
Yellow / Green
See Appandix Stage 4
Diff cover and wiring for type 2
Brown
Coil comander
To green
To black
Black
SA 4686-12
Coil commander to be fitted
on the outside of the axle
Microswitch
Solenoid
Com
Solenoid with coill comander attached
KAM
TM
Type 1
Solenoid with coil comander
as separate part
Type 2
APPENDIX 1 - Bearing information
Crown Wheel Side of Carrier
The KAM 4 Pinion Locking Differential Carrier is designed
to fit the METRIC type Rover Diffs (circa 1987> and later)
fitted with bearing RTC 3095.
Locking Side of Carrier
With our new collar locking system we have supplied a
new bearing which has a larger internal bore ( 52mm )
This is to accept the new locking tube.
If the vehicle has the older (and larger diameter)
"Imperial" type differential or "Pre-Rationalised", a set
of bearing adapter rings will have to be fitted over the
new RTC 3095 bearings to allow it to fit into the case.
Pinion Bearings are the same for all vehicles from
Series II onwards.
Pinion Head Bearing - 593706
Pinion Tail Bearing - 593707
In some Differential Cases bearing RTC 2726 is fitted.
The outer diameter is correct, but the inner diameter is
too small (41.20mm) to accept the KAM Differential
assembly. If this is the case, a RTC 3095 bearing will
have to fitted.
Use the below diagrams to check which size bearing is fitted:-
Pre-Rationalised
Rationalised
73.5mm
Diameter
Height Block Setting
39.5mm
Bearing Cap Bolt 19mm A/F
METRIC TYPE
BEARING RTC 3095
This type only to
be fitted with KAM
diff assy
76.1mm
Diameter
Height Block Setting
38.1mm
Bearing Cap Bolt 3/8"
IMPERIAL TYPE
BEARING 41045
If vehicle has this bearing
fitted, adaptors must
be used with RTC
3095
Bearing RTC2726 will also fit this guide
45.3mm
Inner Bearing Race
RTC 3095
Bearing RTC2726 will not fit this guide
All bearings and adapters that are needed are available through KAM Differentials
APPENDIX 2 - General Differential Data
DATA
Pinion bearing pre-load
Crown wheel run-out
CW/P backlash
7,6 to 13 kgf cm (7 to 12 lb in)
0,10 mm (0.004 in)
0,10 to 0,17 mm (0.004 to 0.007 in)
TORQUE SETTINGS
Crown wheel bolts
Bearing cap bolts
Pinion flange
Diff cover M8 X 16
45 to 55 Ib ft
60 lbf ft
70 to 120 lb ft
8 lb ft
4 Pin Diff Oil Use EP 80 - 90
LSD 4 Pin Oil Use LSD Diff oil
Fill 2 liters only
Fill 2 liters only
APPENDIX 3 - Crownwheel Set Up
When installing the crownwheel and pinion, use engineers blue on the teeth to achieve the correct contact pattern as
illustrated A on the diagram below:Checking bevel pinion to crown wheel engagement
A-Position of marking shows correct engagement
B-Excessive engagement, increase shim thickness
C-Insufficient engagement, reduce shim thickness
The table below corresponds to the Pinion Height deviations. On each KAM pinion head a number is etched (eg 76.2).
Use the table below to ensure the correct size shims for each crownwheel and pinion set. The factory "Standard"
setting is highlighted in blue.
KAM PINION HEIGHT DEVIATION TABLE
Pinion Marking
76.35
76.3
76.25
76.2
76.15
76.1
76.05
76
75.95
Pinion Deviation
-0.006in
-0.004in
-0.002in
0
+0.002in
+0.004in
+0.006in
+0.008in
+0.010in
Pinion Marking
75.9
75.85
75.8
75.75
75.7
75.65
75.6
75.55
75.5
Pinion Deviation
+0.012in
+0.014in
+0.016in
+0.018in
+0.020in
+0.022in
+0.024in
+0.026in
+0.028in
ADDITIONAL NOTES
When fitting the KAM 4 Pinion Diff/LSD into a METRIC type diff casing, please check fitment between bearing caps.
Because of the tight tolerances and variances between crownwheel & pinion set up's and gearing choice etc, one inner
edge of one bearing cap may need around 1mm to be ground or milled off to allow for correct crownwheel adjustment.
KAM Difflock System designed by RM Tracy and KA Mason. Patent filing date 28/02/04.
Text & original Artwork by RM Tracy and property of KAM Differentials Ltd. No copying without prior consent from KAM.
LR16
LR8
LR19
5 off Female
LR14
LR13
LR15
LR12
LR7
LR11
LR11S
(90 / 1998>
rear) 16mm
Standard 8mm
LR10S
LR10
LR50R
Bezel
LR50F
LR33
LR32
LR28
LR28Q
LR2
LR3
LR60
Cross shaft bolt
(x4) M10 or 8
LR50
LR23QP
LR51R Cable Loom 4.5m
LR50R Switch Bezel top Rear
LR50F Switch Bezel top Front
Kit 3 parts
Optional extra
Bearing Adapter LR48I
to fit Imperial diff Imperial
casing
LR48IK
LR47P
LR53 Relay + Fuse 30A
C clip for locker quill tube
LR54 Welding fillet (x2)
Sun gear thrust plate(2 or 1.5mm) LR56
16mm P38 Puma adapter
LR57 Solenoid wiring P-clip
M or I Bearing adjuster LR58 M & F Wiring Connector Pack
Bearing adjuster lock tab LR59
Switch Body
LR60 Steel bush for wiring gland
KAM Carrier Bearing x 1
LSD preload screw (x8)
LSD Collar 24spline (1)
Quill Locking Tube x1
LR42
Thrust washers (x4 16-18mm) LR43Q
LSD sun gear No boss (x1) LR44Q
Belleville spring (A or B)
LR45Q
LSD clutch Out A Inner B LR46
Sun gear with boss (x1)
LR47P
Spacer plate (A B C D E) LR48
Carrier bolt (x12)
LR49
LR48 M or I
Metric or
Imperial
15m adapter and Longer fork
LR49
Puma 110 P38
2004> Rear Diff only
LR44Q
Optional extra
RTC3095
Metric Bearing
LR39
Pinion Gears (x 4 16-18mm)
Shallow cases to mis rear
tank
LR1 (Standard cases)
LR1S (90 / 1998> rear)
LR9
LR40 (M10 or M8)
Pinion cross shaft 16 or 18mm LR41
LR7
LR7L (20mm)
LR8
LR31
LR32
(P) Actuator fork P = P38
LR33
Sliding (locking) dog Quill LR34
Sliding dog spring
LR35
Sliding dog washer (x2)
LR36
Sliding dog circlip
LR37
LR38
Carrier locking boss end
Carrier Centre 16 or 18mm LR39
Carrier flanged end LR30P +P38 LR40
Solenoid nut Nylock (x2)
Actuator fork screw CSK
LR4
LR6
LR54
LR22
LR27Q
LR23Q (P38 Puma add P)
LR41
(10 or 14 teeth)
Red indicates Locker +LSD components
LR38A (12) LR38D (6)
LR35A (5.25)
Blue indicates non-LSD components
LR35B (3.6mm) LR38B(10) LR38E (4)
LR38C (8) (mm)
Green indicates Upgradeable parts
LR46A (2mm)
LR35A (5.25)
LR46B (1.5mm)
LR35B (3.6mm)
LR37
LR36A Outer
LR36B Inner
LR42
LR34
4 Pin/LSD
LR41
LR24 ( None Quill locker)
LR24Q
LR25Q
LR26Q
(2 or 1.5mm)
LR46AorB
LR20
LR34
LR43Q
(90 / 1998> rear)
LR45Q
LR31
LR30
LR30P
(Rover) (P38)
LR1 Diff cover LR1S 90/1998>Rear LR11 Solenoid mount LR11S 90/1998> Rear LR21
LR2 Wiring gland
LR12 Warning lamp microswitch LR22
LR23Q
LR3 Wiring gland O-ring
LR13 Microswitch bracket
LR24Q
LR4 Oil filler plug
LR14 Microswitch rivets (x2)
LR5R+B 2M Red & Black Battery Cable LR15 Cable tie, short (X2) 200mm LR25Q
LR6 Ali bush for oil filler plug
LR16 M6 Anti Vibration washer (x3) LR26Q
LR7 M6 X 16 Cover cap head (x15)LR17 Solenoid with or without comander LR27Q
LR8 M6 Flat washer form C (x15) LR18
LR28Q
LR9 Diff cover gasket
LR19 M6 x 12 cap head (x3)
LR29
LR10 Mounting ring 8mm LR10S 16mm LR20 Cable tie, long (X2) 580mm LR30
all drawings copyright c kamdiffs 2005
5 off Male
Solenoid with coil comander
as separate part
SA 4686-12
Type 1
LR17
LR16
LR19
Coil comander
Type 2
LR19
LR57
LR21
LR50
LR29
LR58M
LR58F
LR51R
LR5R+B
LR53
TM
KAM
Ref: KAM Diff Locker Fitting V5 2012
APPENDIX 4- Parts List - Rear and Front Axle Quil locker + LSD
The KAM Differentials Ltd
Wiring gland “up date”
Please note a change to the fitting instructions. The wiring gland now enters
through the top of the axle casing and not the aluminium cover as on previous
versions. This makes removal of the diff pan considerably easier. The Steel
insert requires a hole drilling or cutting with a hole saw of 19mm. The steel
insert can then be welded or bonded around it’s edge and the gland then
screwing home. The wiring loom should be held out of harms way with a rubber
lined P clip. (provided).
APPENDIX 5-
Up Grade Kit from New Quill Locker To LSD Locker
Remove the spacers from LR30 and replace with clutch pack, LSD collar and sun gear. This kit
only converts one side. See set up instructions for fitting front or rear
KAM
TM
Part No: C-KIT-QL1 (New Locker up grade kit one side)
LR41
LR35 (5.25 or 3.6mm)
LR36A Outer
LR36B Iner
LR42
LR34
Up Grade Kit From Old Locker To New Quill Locker
This up grade kit uses any 24 spline half shafts.
LR34
LR46 (2 or 1.5mm) LR28Q (14 teeth)
LR44Q
LR45Q
Part No: D-LR-UPG-QIL-SN ( P38 Short nose Diff )
LR43Q
LR24Q LR25Q
LR26Q
LR23Q (P38 Puma add P)
LR41
LR27Q
all drawings copyright c kamdiffs 2005
LR1 Diff cover
LR2 Wiring gland
LR3 Wiring gland O-ring
LR4 Oil filler plug
LR5R+B 3M Red & Black Battery Cable
LR6
Insert Oil Filler
LR7 M6 X 18 Screw (x15)
LR8 M6 Flat washer form C (x15)
LR9 Diff cover gasket
LR10 Mounting ring assembly
LR21 Solenoid nut (x2)
LR31
LR11 Solenoid mount
LR12 Warning lamp microswitch LR22 Actuator fork screw
LR32
LR23Q P Actuator fork P = Puma LR33
LR13 Microswitch bracket
LR24Q Sliding (locking) dog Quill LR34
LR14 Microswitch rivets (x2)
LR15 Cable tie, short (X2) 200mm LR25Q Sliding dog spring
LR35
LR36
LR16 M6 Anti Vibration washer (x5) LR26Q Sliding dog washer (x2)
LR37
LR17 Solenoid with or without comander LR27Q Sliding dog circlip
LR18 M6 X 20 Screw (x3)
LR28Q Carrier locking boss end LR38
LR19 M6 Form A flat washer (x2) LR29 Carrier Centre 16 or 18mm LR39
LR20 Cable tie, long (X2) 580mm LR30 Carrier flanged end LR-P38 LR40
Pinion cross shaft 16 or 18mm LR41
Pinion Gears (x4 18mm) LR42
LSD preload screw (x8)
LR51R Cable Loom 4.5m
LR52
LR53
LR54
Belleviue spring washer (x1)LR45Q C clip for locker quill tube
LR55
LSD clutch Out 4 & Inner3 LR46 Sun gear thrust plate(2 or 1.5mm) LR56
Sun gear with boss (x1)
LR47P 18mm P38 Puma adapter
LR57
Spacer plate (x4)
LR48 M or I Bearing adjuster LR58
Carrier bolt (x12)
LR49
Bearing adjuster lock tab LR59
Cross shaft bolt (x4)
LR50
R or F Operating switch LR60
LSD Collar 24spline (1)
LR43Q Quill Locking Tube x1
Thrust washers (x4)
LSD sun gear No boss (x1) LR44Q KAM CarrierBearing x 1
Relay + Fuse 40A
Welding fillet (x2)
Solenoid wiring P-clip
Wiring Connector Pack
Steel plug for wiring gland
Parts List - Rear and Front Up Grade Kit Quil locker +LSD
Part No: D-LR-UPG-QIL-LN ( Rover Long nose Diff )