Quaife diff locks on Mercedes Benz W124 E60 AMG

Mercedes Benz W124 needed diff locks Quaife to be installed.

You can say that along the way we also made complete restoration :))))

Checking up the thermal gap, dissection, defects identification, wash up, preparation for sandblasting treatment.
It is extremely important to cover properly bracing planes and surfaces that are not meant to be treated.

For that very purpose we created a rigging.
We ordered all the necessary consumables: bearings, gaskets, rings, etc.
Painting with a powder paint gives a great quality coating, resistant to tough usage conditions.
Assembling also required rigging to regulate the driving gear cantilevered bearing tension.

Some desiner thoughts…
Car manufacturers are always restricted by rigid limitations of mass production, while exchanging the engine for biggest possible for the sub-compartment space, transmission usually is left the same in a tradition “whatever, it’ll hold”..

The main pair is a hypoid gear with a free differential.

V8 engine volume is 5.0L produces up to 381 HP with 5600 rpm., with the torque up to 402 Нм with  3900 rpm.

Nominally loaded engine produces sufficient amount of heat in the main pair, adding differential locking we get few kilowatt heater.

The car owner expressed the desire to change stock reducer lid.
To decrease the heat the lid was designed consisting of a body, lower radiator and two assisting lids.

As we know, the body always “floats up”.

We had a task to shift the working body  (oil) to the lower radiator, that is well ventilated and has the biggest possiblle surface.
In automotive world an electric pump is usually used and radiator is moved out into the maximum possible ventilation zone. It’s called active cooling.
As they say, necessity is the mother of invention, so we are going to choose different path..

Slave gear lower half is constantly submerged into oil bath.

While rotating it throws oil at the back lid. That was decided to use in our favor!

Oil separator or oil gatthering pocket is put on the back lid.

Post height is sufficient enough for gravitational channel pumping, that are between the body and  the lower radiator.

Creating ribs on the lower radiator oil channel allows for the heat to be channelled away without creating excessive resistance.

Lower radiator design is executed in the “quadratisch – praktisch – gut” tradition..

According to performed thermal calculation it is obvious that rear part of the radiator is excessive, but that is a car owner’s request.

The design and the coordination took a few weeks.
All the parts were manufactured on our equipment, material used is D16T.

original reducer Mercedes Benz W124 E60 AMG pic1

original reducer Mercedes Benz W124 E60 AMG pic2

measuring reducer lid dimentions Mercedes Benz W124 E60 AMG Pic1

measuring reducer lid dimentions Mercedes Benz W124 E60 AMG Pic2

measuring reducer lid dimentions Mercedes Benz W124 E60 AMG Pic3

measuring reducer lid dimentions Mercedes Benz W124 E60 AMG Pic4

designed reducer lid & cooling radiator for Mercedes Benz W124 E60 AMG pic1

designed reducer lid & cooling radiator for Mercedes Benz W124 E60 AMG pic2

designed reducer lid & cooling radiator for Mercedes Benz W124 E60 AMG pic3

designed reducer lid & cooling radiator for Mercedes Benz W124 E60 AMG pic4

designed reducer lid & cooling radiator for Mercedes Benz W124 E60 AMG pic5

heat balance of reducer lid & cooling radiator surface for Mercedes Benz W124 E60 AMG pic1

heat balance of reducer lid & cooling radiator surface for Mercedes Benz W124 E60 AMG pic2

 

heat balance of reducer lid & cooling radiator surface for Mercedes Benz W124 E60 AMG pic3

 

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