Limited Slip Clutch Pack

This procedure covers removal and replacement of the limited slip differential clutch pack assembly in the front or rear differential of a 4WD Dodge Ram 2500 with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Limited slip clutch pack kit (includes friction and steel plates) × 1 — Use OEM specification for your differential model
• Differential cover gasket or RTV sealant × 1 — Use OEM specification
• Limited slip additive × 1 — Mopar or equivalent
• Pinion shaft lock pin or bolt × 1 — Inspect and replace if damaged
• Differential shims (assorted) × 1 — Have selection available for backlash adjustment
• New cotter pin for axle nut (if applicable) × 2 — Use OEM specification

Fluids

• 75W-90 synthetic gear oil — 5.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock front wheels securely
3. Raise rear of vehicle and support on jack stands at frame rails
4. Allow differential to cool if recently operated
5. Mark driveshaft and yoke alignment for reassembly reference
6. Clean exterior of differential housing with degreaser to prevent contamination

Procedure

1. 1

   Remove rear wheels and drain differential
   Remove both rear wheels. Place drain pan under differential cover. Remove differential cover bolts in crisscross pattern starting with bottom bolts. Carefully pry cover loose and allow gear oil to drain completely. Remove cover and gasket material.
   Torque spec

   Wheel Lug Nuts183 Nm (135 lb-ft)

   Differential Cover Bolts35 Nm (26 lb-ft)
2. 2

   Disconnect rear driveshaft
   Mark the relationship between driveshaft and pinion yoke with paint or scribe. Remove driveshaft u-joint strap bolts or CV bolts at the differential yoke. Support driveshaft and remove from pinion flange. Secure driveshaft out of the way or remove completely.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)

   Driveshaft Bolts75 Nm (55 lb-ft)
3. 3

   Measure and record gear backlash
   Mount dial indicator against ring gear tooth face. Hold pinion steady and rock ring gear back and forth to measure backlash. Record measurement at 4 equally spaced positions around ring gear. Backlash should be 0.127-0.229mm (0.005-0.009 inches). This measurement is critical for reassembly verification.
   ℹ️Recording original backlash is essential for proper reassembly. Incorrect backlash causes noise and premature gear wear.
4. 4

   Remove axle shafts
   Remove pinion shaft lock bolt or pin from differential case. Slide pinion shaft out of case carefully, noting orientation. For full-floating axles (common on 2500 HD models), remove the axle flange bolts and withdraw the axle shafts from the housing. For semi-floating C-clip axles, push axle shafts inward and remove C-clips from axle shaft button ends. Carefully withdraw both axle shafts from housing, being careful not to damage axle seals.
   ⚠Do not damage axle seals during removal or fluid will leak. Replace seals if any damage occurs.
5. 5

   Install differential spreader and remove carrier
   Install differential spreader tool on housing following manufacturer instructions. Spread housing a maximum of 0.381mm (0.015 inches) while monitoring with dial indicator. Mark bearing cap orientation to housing. Remove bearing cap bolts. Carefully pry carrier assembly out of housing using pry bars at spreader tool mounting points. Remove spreader immediately after carrier is free.
   ⚠️Never spread housing more than 0.381mm (0.015 inches). Excessive spreading will permanently deform the housing.
   ⚠Do not leave housing in spread position longer than necessary. This can cause permanent damage.
6. 6

   Disassemble carrier and remove old clutch pack
   Place carrier assembly on clean workbench. Mark the relationship between ring gear and differential case. Remove ring gear bolts (if accessing through case). Remove side bearing retainers or adjusters noting positions and shim thickness. Remove differential case halves bolts and separate case. Remove spider gears, side gears, clutch packs, and thrust washers. Keep components organized and note assembly order. Inspect all components for wear, scoring, or damage.
   ℹ️Take photos during disassembly to reference exact positioning of clutch plates, shims, and components.
7. 7

   Clean and inspect all components
   Thoroughly clean all differential components with solvent. Inspect ring gear and pinion for wear patterns, scoring, or chipped teeth. Inspect differential case for cracks or wear. Inspect spider gears and side gears for excessive wear or damage. Inspect bearing races and rollers for pitting or scoring. Replace any damaged components. Verify new clutch pack matches original specification.
8. 8

   Install new clutch pack assembly
   Lubricate all new clutch plates with gear oil. Install side gears with new clutch packs in correct alternating pattern (friction plate, steel plate, friction plate, etc.) as specified in clutch pack kit instructions. Install thrust washers in proper positions. Install spider gears and pinion shaft, ensuring proper mesh with side gears. Verify clutch pack preload by measuring resistance when rotating side gears - should require moderate force.
   ℹ️Clutch pack plate order and orientation is critical. Consult clutch pack kit instructions for exact sequence.
9. 9

   Reassemble differential carrier
   Align differential case halves ensuring proper case alignment. Install case bolts and torque to the OEM specification for your specific differential model (confirm value in factory service manual before assembly). Install side bearings using bearing driver if removed. Install bearing adjusters or shims to original positions. If ring gear was removed, align marks and install ring gear bolts with thread locker, torquing in crisscross pattern.
10. 10

    Install carrier assembly into housing
    Clean differential housing thoroughly. Install differential spreader tool and spread housing maximum 0.381mm (0.015 inches). Lubricate side bearing bores with gear oil. Carefully install carrier assembly into housing, ensuring bearing caps align with previous position marks. Install bearing cap bolts finger tight. Remove spreader tool immediately. Torque bearing cap bolts to specification.
    ⚠Ensure bearing caps are oriented correctly per original markings. Reversed caps will cause binding and failure.
11. 11

    Adjust backlash and verify gear mesh
    Adjust side bearing preload using bearing adjusters or shims. Use dial indicator to measure ring gear backlash at multiple points. Adjust until backlash is within 0.127-0.229mm (0.005-0.009 inches) and varies no more than 0.051mm (0.002 inches) around the ring gear. Verify gear tooth contact pattern using marking compound if available. Recheck backlash after final adjustment.
    ℹ️Backlash adjustment requires patience and multiple measurements. Improper adjustment causes gear noise and premature failure.
12. 12

    Install axle shafts and pinion shaft
    Carefully install both axle shafts into housing, ensuring splines engage with side gears. Push axle shafts fully into differential. For full-floating axles, reinstall the axle shafts and torque the axle flange bolts to specification. For semi-floating C-clip axles, install C-clips on axle shaft button ends and pull axle shafts outward to verify C-clips are seated. Align pinion shaft with lock bolt hole and install shaft. Install new pinion shaft lock bolt or pin and torque to the OEM specification for your differential model (confirm value in factory service manual).
13. 13

    Install differential cover and fill with gear oil
    Clean cover and housing mating surfaces thoroughly with plastic scraper. Install new gasket or apply thin bead of RTV silicone to cover (if no gasket used). Install differential cover and torque bolts in crisscross pattern. Fill differential with 75W-90 synthetic gear oil to bottom of fill hole (approximately 3.5-4 quarts for the rear differential; fill to the bottom of the fill hole and verify). Add limited slip additive per the additive manufacturer and OEM specification (typical amount varies by axle; confirm correct quantity for your differential). Install fill plug.
    ℹ️Limited slip differentials require special additive in addition to gear oil. Failure to add will cause chatter and clutch damage.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
14. 14

    Reinstall driveshaft and wheels
    Align driveshaft to pinion yoke using alignment marks made during disassembly. Install driveshaft u-joint straps or CV bolts and torque to specification. Verify driveshaft rotates freely. Install rear wheels and torque lug nuts in star pattern.
    Torque spec

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)

    Driveshaft Bolts75 Nm (55 lb-ft)

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Ensure all torque specifications have been met, particularly bearing caps, driveshaft bolts, and wheel lug nuts
2. Verify differential has proper fluid level and limited slip additive has been added
3. Double-check that no tools or parts remain in or around the differential housing
4. Verify axle shafts are fully seated with C-clips engaged

Verification

• Lower vehicle and test drive in safe area. Listen for abnormal gear noise, whine, or vibration
• Perform several figure-8 turns in both directions at low speed to activate limited slip clutches
• Limited slip should engage smoothly without chatter. Some initial chatter is normal until clutches break in
• Recheck differential cover for leaks after test drive. Slight seepage within first 24 hours is normal but should stop
• Verify proper limited slip operation by performing controlled wheel spin test on loose surface - both wheels should rotate together
• Recheck gear oil level after test drive and top off if necessary
• Check driveshaft u-joint bolts for proper torque after initial test drive

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