Clutch Assembly Clearance Adjustment

Fig. 16 Measuring case assembly depth for clutch pack clearance. Models w/limited slip differential:

Fig. 17 Measuring case cover flange depth for clutch pack clearance. Models w/limited slip differential:

1. Install spacer (500, 600 and 700 series only), outer plate, inner plate, thrust ring and side gear in differential case, ensuring side gear is properly seated. Thrust washers, stepped washers, and diaphragm springs, as equipped, are not installed until assembly clearances have been measured.
2. Install differential pinion assembly, ensuring pinion shafts are located in thrust ring notches.
3. Install remaining side gear with hub facing up, then the thrust ring, inner plate and outer plate.
4. Ensure components are properly seated, then measure distance ``A'' from case cover mounting surface to top of outer plate, Fig. 16, and record measurement.
5. Measure dimension ``B'' from raised portion of case cover to cover mounting surface, Fig. 17, and record measurement.
6. Measure combined thickness ``C'' of diaphragm springs, and record measurement.
7. An assembly clearance of .004 to .016 inch is necessary to prevent total compression of clutch pack diaphragm springs. Obtain total assembly clearance as follows:
a. Add recorded case cover height ``B'' to total diaphragm thickness ``C,'' and record sum.
b. Subtract sum obtained in previous step from assembly height ``A'' to obtain clutch assembly clearance.
c. If remainder obtained in previous step is not .004 to .016 inch, replace outer plates as needed to obtain specified clearance.
d. If assembly clearance is less than specified, select and install thinner outer plates. If assembly clearance is greater than specified, install thicker outer plates. Select plates to obtain clearance as close to .004 inch as possible.
e. Install selected outer plates as outlined and ensure assembly clearance is within specifications.
8. Remove selected components from case, keeping components in order for final assembly.