THE KAM LAND-ROVER Differential Lock
all drawings copyright c KAM diffs 2006 filename: DIFLOKFLY4
Patents Pending GB0404547.2 & PCT/GB05/000701
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.
The System
The solution was to utilise 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
halfshaft until it locks onto the carrier locking boss. This method
allows a smooth engagement of the dog gears without
detriment to the solenoid operation. As a failsafe, the system
will always disengage.
The Kit
Within the kit, you will have all the necessary parts to
install the diff locker. These include:
Heavy Duty 4 Pinion Carrier
Heavy Duty Half Shafts
Locking Mechanism
Solenoid
Mounting Plates
Diff Cover
Oil filler plug
Sight glass
Gaskets
Driving member hubs
Wiring loom
Relay & fuseholder
Quality Operating switch
Warning lamp microswitch assy
Bearing adjuster nut and lock tab
All nuts, bolts and washers
Studlock
Optional extra's and upgrades:
Extra heavy duty halfshafts (aerospace steel)
Limited Slip 4 Pinion Differential (fully adjustable)
Flange Sealant (to ensure oil tightness of welds)
KAM 4 Pinion Differential
The KAM Heavy Duty 4 Pinion Differential Carrier included
in the kit (and also available seperately) is upgradable to a
Limited Slip Differential.
The Carrier is a 3 part unit which has been designed to be
easily assembled. To upgrade the standard 4 pin carrier the
sun gears and spacer plates are simply replaced by a set of
clutch packs, springs, adjuster grub screws and specially
modified sun gears. The LSD then features adjustable
preload and adjustable slip/grip characteristics, making it
a very versatile piece of equipment.
Fitting
To install the KAM Diff Locker, the exisiting Diff Pan needs to
be removed (by angle grider, plasma cutter or gas torch etc)
and a small slot cut, to allow actuator fork movement . Then
the area needs to be ground flat and cleaned.
There are 2 methods of fitting the 8mm steel mounting ring,
i) by means of welding or 2) by bonding, with super high
strength polymer based "Power Adhesive" which can be
supplied as an optiona extra (product as used for bonding
car and railway train carriage bodywork).
Once the Mounting Ring has been fitted, the Heavy Duty
4 Pinion Differential is fitted, along with the Heavy Duty
half shafts and locking mechanism. The Solenoid can then
be bolted in place and wired up.
A purpose made electrical cable is used to connect the solenoid
to the main operating switch, via a relay and fuse. The operating
switch encompases a warning lamp, which only illuminates when
the diff lock is engaged.
A removeable Polycarbonate cover neatly encloses the Diff Lock
assembly onto the axle, this features a useful sight glass to
ensure oil level is correct.
A fully illustrated set of instructions are included to make fitting
the kit as simple as possible.
KAM Strengthened Half Shafts
The kit includes our well proven half shafts and driving member
hubs as standard. We have recently improved heat treatment of
these shafts and have introduced dedication shafts for the
different Land Rover range of vehicles, please advise us of your
vehicle type when ordering, to ensure the correct shafts.
Retail Prices (introductory offer prices)
LAND ROVER Rear axle £650
LAND ROVER Front axle £675
Rear Locker with LSD upgrade £810 KAM
Limited Slip Differential only £395 TM
Prices shown exclude VAT payable at 17.5% www.kamdiffs.com