Re: XG ute diff LSD conversion
Sorry in advance for this essay-length post...
I was changing it myself and i'm stoked to say that last night i took it for a test drive and all appears to be well.
It's definitely not a small job, you have to take the entire rear axle out of the vehicle and i wouldn't attempt this without the Gregory's Workshop manual, but i could scan the relevant pages and e-mail them to you if you like.
There are a couple of critical points to take note of:
1. You need the axles as well as the diff centre as the LSD centre is wider and the corresponding axles are shorter. That was the case with mine anyway.
2. You need to swap the crown wheels over because they are matched to the pinion, and they're probably different ratios anyway (I'd imagine the XG is 3.27 and the EBII is 3.23). When doing this keep in mind that the retaining bolts are LEFT HAND thread and torqued to about 150Nm so you'll probably need to take them to a workshop with a rattle gun and get them to do it for a small fee or a few beers.
Once you get the diff out of your car you need to get the centre out of your diff, this is not as easy as it sounds. The diff centre is actually a few thou's wider than the gap it has to fit into so it's well and truly wedged in there. Technically you're meant to use a diff housing spreader for this job but they're expensive and hard to come by.
I've heard of a few 'alternative' techniques like using a jack to flex the entire diff, and even the professionals I spoke to said that they just used crow bars, but i had the feeling that these had the potential to cause problems rather than solve them. I ended up putting some light chain around the diff centre, attatching it to a chain haul, and then raising it while standing on the housing and it came out quite easily but make sure you've got the axle shafs out so they don't get in the way. Also you MUST keep track of which side the shim and bearing cup were in and make sure they go back to where they came from.
Getting it back in involves a lot of gentle tapping and even more patience.
If it drops in too easily that means you need wider shims and don't use the diff untill you get it right.
Lastly fill the diff with the correct grade of lubricant, Castrol LSX 90 for example.
After all of this work the backlash will pobably be wrong, but there is a chance that it will be alright, lucky for me mine was. I've been told by a diff specialist that if it's wrong you'll know about it
(grinding/whining/clunking etc.) and if this is the case you'll have to get it set up by a specialist, i was quoted $100-$150 if i took the diff out and over to them myself.
You'd want to be a moderately competant home mechanic to attempt this but with no experience in diffs other than a workshop manual i managed to get the job done in one (fairly busy) day.
If i can work out some way to send you a private message I'm happy to give you my mobile number and you can give me a call when you're attempting the job, and i can tell you it's definitely worth the effort, driving my car is a whole new experience.