Final Assembly

Fig. 13 Limited slip differential exploded view.:

Coat all components with specified axle lubricant during assembly.
1. Install side gear trust washer (2) with oil grooves facing down and diaphragm spring (3), Fig. 13, with concave side facing up.
2. Install stepped washer with smooth side toward diaphragm spring and tab engaged in case notch.
3. Install spacer and clutch pack diaphragm spring (5), with concave side of spring facing up.
4. Install outer plate, inner plate and thrust ring, ensuring guide tabs are properly engaged.
5. Install side gear, turning gear to engage inner plate splines or guides.
6. Install differential pinion and shaft assembly, and the remaining side gear and pressure ring, ensuring components are properly seated.
7. Install inner plate, outer plate and clutch pack diaphragm spring (5), Fig. 13, with concave side of spring facing down.
8. Install side gear thrust washer (2) and diaphragm spring (3) in case cover, with thrust washer oil grooves facing cover and concave side of spring facing inside of case.
9. Install stepped washer in cover with smooth side toward diaphragm spring and tab engaged in cover notch. Use grease to retain thrust washers and spring in cover during assembly.
10. Temporarily install cover assembly, ensuring thrust washers and springs remain in place, and evenly torque bolts to 22-24 ft. lbs.
11. Install drive flanges, then mount assembly in fixture with one drive flange blocked to prevent rotation.
12. Fabricate a suitable tool to allow remaining drive flange to be rotated with torque wrench, then check assembly slip torque by rotating one flange while the other flange is blocked.
13. Slip torque should be 36-54 ft. lbs. for 500 and 600 series models or 80-94 ft. lbs. for 700 series models. Slip torque is controlled by the thickness of the outer clutch plates. If slip torque is less than specified, install thicker outer plates; if torque exceeds specifications, install thinner outer plates. When replacing clutch plates to adjust slip torque, ensure clutch assembly clearance is maintained within the specified .004 to .016 inch.
14. After slip torque is properly established, install case cover as previously outlined using thread locking compound on retaining bolts, then evenly torque bolts to 22-24 ft. lbs. in crossing pattern.