Assemble
TOOLS REQUIRED^ J-8592 Long Driver Handle
^ Or Equivalent
1. Lubricate thrust face of side gears, plates and discs with the proper limited slip rear axle lubricant.
2. Plates and discs in exactly in the same position as they were removed, regardless of whether they are new or original.
3. Differential plate retainer to ears of plates.
NOTE: Make sure both retainers are completely seated on ears of plates.
4. Clutch pack and side gear into bottom side gear bore. Make sure clutch pack stays assembled to side gear splines, and that retainers are completely seated into packets of case.
NOTE: To prevent clutch pack from falling out of case, hold clutch pack in place by hand while repositioning case on bench.
5. Other side gear and clutch pack. Make sure clutch pack stays assembled to side gear splines, and retainers are completely seated into pockets of case.
6. Hold clutch pack in position and insert screw cap & cap and forcing screw. Tighten forcing screw into bottom adapter to hold both clutch packs in position.
7. With tools assembled to case, position case on yoke shaft by aligning splines of side gear with those of shaft. Tighten forcing screw to compress clutch packs in order to provide clearance for pinion gears.
8. Pinion gears: Place the pinion gears into the differential 180 degrees apart.
9. While holding gears in place, insert LSD service adapter with long drive handle (J-8592) in differential shaft hole of case. Pull on long drive handle (J-8592) and rotate case, allowing gears to turn. Make sure that holes in pinion gears align with holes in case: It may be necessary to adjust tension on forcing screw to rotate case.
10. Tighten forcing screw to compress the clutch packs, to allow installation of tapered washers.
11. Lubricate spherical washers, and assemble into case. Use a small screwdriver to push washers into place. Remove tools.
12. Position differential shaft in case and drive in with hammer. Be sure retaining pin hole of differential shaft is properly aligned to allow installation of retaining pin. Be sure that thrust washers and differential pinion gears are aligned with the differential case. Install new retaining pin to proper depth using a punch. Stake retaining pin at both ends of case.