ROADSAFE DDLC200 Diff Drop Instructions

ROADSAFE DDLC200 Diff Drop

Product Information

The product is a Diff Drop kit designed for the Landcruiser 200 Series. The product code is DDLC200.

The kit includes the following components:

• 6 x M10xP1.25 x 50L bolt
• 6 x M10 spring washer
• 6 x M10 flat washer
• 6 x 20 x 15mm Machined Alloy Spacer
• 1 x M8xP1.25 x 50L bolt
• 1 x M8 spring washer
• 1 x M8 flat washer
• 2 x M14xP1.5 x 150L bolt
• 3 x 30 x 65mm Machined Alloy Spacer
• 2 x M14xP1.5 nyloc nut
• 1 x M14xP1.5 x 80L bolt
• 1 x 6mm Machined Alloy Spacer

The kit is suitable for Landcruiser 200 Series vehicles with KDSS and 2016 models. It is designed to lower the front diff by 25mm, reducing the angles CV joints need to operate on.

Product Usage Instructions

1. Secure the vehicle and apply the handbrake.
2. If the vehicle has a bash guard over the diff mounts, use the six smaller spacers and bolts provided to space down the bash guard.
3. Remove the front diff mount bolts and insert the large spacers and new 150mm x M14 bolts supplied with nyloc. Leave them loose until all spacers are installed.
4. Loosen the back mount behind the cross member to allow it to drop. Insert the small 6mm spacer with the new 80mm x M14 bolt with nyloc. Note that you only need access to the rear wall as shown in figure 4.
5. Raise the diff into location and tighten all mounting bolts.
6. If diff mount-guards are fitted, use the remaining M8 bolts, washers, and spacers supplied to space them down by fitting spacers between the mount and chassis.
7. Once the diff mounts are tight, lift the center bash plate into position and install the remaining large spacer into the center of the cross member using the longer M8 bolt. Note that one of the three large spacers supplied with the kit is only for use with vehicles with factory bash plates to fill the gap between the bash plate and the cross member at the jacking point.

Please note that it is recommended to have the installation done by a specialist 4WD mechanic.

Kit Contents

• 6 x M10xP1.25 x 50L bolt
• 6 x M10 spring washer
• 6 x M10 flat washer
• 6 x 20 x 15mm Machined Alloy Spacer
• 1 x M8xP1.25 x 50L bolt 1 x M8 spring washer
• 1 x M8 flat washer
• 2 x M14xP1.5 x 150L bolt
• 3 x 30 x 65mm Machined Alloy Spacer
• 2 x M14xP1.5 nyloc nut
• 1 x M14xP1.5 x 80L bolt
• 1 x 6mm Machined Alloy Spacer

Suitable for Landcruiser 200 Series. Designed to allow for the front diff to be lowered by 25mm, thus reducing the angles CV joints need to operate on. Suitable for vehicles with KDSS and 2016 models.

Shows two main spacers installed from rear view

Close up of driver side main spacer

Close up of passenger side main spacer

6mm spacer installed into diff mount under passenger side of vehicle

Shows small 6mm spacer installed into diff mount under passenger side of vehicle (side view)

Red dot indicates the larger main diff drop spacers and bash plate mount, including new bolts. Yellow dots are the small spacers with new bolts. Red arrow locates the 6mm spacer.

1. Secure vehicle. Ensure hand brake is applied. Late model 200 Series have a bash guard over the diff mounts. Early models do not. The six smaller spacers & bolts are used in the later models to space down the bash guard.

2. Remove front diff mount bolts & insert large spacers and new 150mm x M14 bolts supplied with nyloc—reuse factory washer. Leave loose until all spacers are installed.

3. With the rearmost mount as pictured, you will need to loosen the back mount behind the cross member to allow it to drop. Insert small 6mm spacer with new 80mm x M14 bolt with nyloc.
   Note: Not completely; just need access to rear wall as per figure 4.

4. Raise diff into location and tighten all mounting bolts.

5. Use remaining M8 bolts, washers & spacers supplied to space down diff mount-guards if fitted by fitting spacers between mount & chassis.

6. Once diff mounts are all tight, lift centre bash plate into position and install the remaining large spacer into the centre of the cross member using the longer M8 bolt.

NOTE: There are three large spacers supplied with the kit. One of these is only for use with vehicles with factory bash plates, to fill the gap between the bash plate & the cross member at the jacking point.
roadsafe.com.au
A division of Specialist Wholesalers Pty. Ltd.
ABN 64 163 280 279
VIC PH: 03 8687 1700
QLD PH: 07 3737 7420
Email: sales@roadsafe.com.au

References

• roadsafe.com.au

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