1992 Volvo 240 Differential Carrier

Are you intimidated by differential repair? Well, I was and here is my process. Thanks to Robert on the Facebook Volvo 240 fan page for his help and the part, Dave Barton at 240turbo.com for all the good info, and @lowrangoffroad for their video about checking differential ring gear lash. Link:    • How to Measure Differential Backlash  

I am a home mechanic who has driven and worked on 240s for almost 20 years.

Helpful links:
https://www.turbobricks.com/forums/showthr...
https://forums.turbobricks.com/showthread....
http://forums.turbobricks.com/showthread.p...

https://people.physics.anu.edu.au/~amh110/...

https://www.240turbo.com/volvorearends.html

https://www.240turbo.com/volvorearends.htm...

TrueTrack diff carrier: a good replacement but need to follow some of the steps above:
https://www.summitracing.com/parts/dtl-912...
and the bearings needed:
https://www.summitracing.com/search/part-t...

Torque values:
ring gear: 55 ft-lbs
carrier bearing caps: 50 ft-lbs
rear wheel bearing caps: 25 ft-lbs

rear end info (this one- 1992 245 w/ m47):
ratio: 3.31
splines: 27
type: 1031 (dana 30)
original carrier: LSD 2.2
new carrier: g80
fluid for g80: 75w90 gl-5 gear oil - no limited slip additives
Preload: you want the carrier with its bearings to be a tight fit (need a few taps from a plastic mallet)
Lash: .005"-.007"
always keep your ring and pinion gears as a matched set.
you may get lucky like me putting a used carrier into the same type case- you want between .005 and .007" lash (play). ive been told .004" is acceptable for moderate use. Mine was .007". I didn't have to adjust the shims.