Limited Slip Clutch Pack

Replace the limited-slip differential clutch pack assembly, requiring differential disassembly, clutch pack replacement, and refill with gear oil and limited-slip additive.

Warnings

Tools required

Parts

• Limited-slip clutch pack kit × 1 — Use OEM specification or Dana 44 equivalent
• Differential cover gasket × 1 — Use OEM specification
• Differential bearing shim set × 1 — Use OEM specification
• RTV silicone gasket maker × 1 — Permatex Ultra Grey or equivalent
• Thread locker (medium strength) × 1 — Loctite 242 or equivalent

Fluids

• 75W-90 GL-5 gear oil — 3.5 qt
• Limited-slip differential additive — 0.5 qt

Preparation

1. Park vehicle on level concrete surface and set parking brake.
2. Loosen rear wheel lug nuts while vehicle is on ground.
3. Raise rear of vehicle and support securely on jack stands positioned under rear frame rails.
4. Remove both rear wheels.
5. Place drain pan under differential.
6. Allow differential to cool if recently driven.

Procedure

1. 1

   Drain differential fluid
   Remove the differential cover bolts in a crisscross pattern. Once cover is loose, allow fluid to drain completely into drain pan. Remove cover and set aside. Clean magnetic drain plug if equipped and inspect for metal shavings indicating wear.
   Torque spec

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

   Mark and measure ring gear backlash
   Before disassembly, use a paint marker to mark the relationship between carrier caps and differential housing for reassembly. Mount dial indicator on housing with tip against ring gear tooth. Rock ring gear back and forth to measure backlash. Record this measurement (should be 0.005-0.008 inch). This establishes baseline for reassembly.
   ℹ️Original backlash measurement is critical for proper reassembly. Label measurement on tape attached to housing.
3. 3

   Remove carrier bearing caps
   Remove the 4 bolts securing each carrier bearing cap (8 bolts total). Caps are marked with punch marks or cast marks - verify these match your paint marks. Carefully lift caps straight up to avoid damaging bearing races. Keep caps with their respective sides.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
4. 4

   Remove differential carrier assembly
   Install differential spreader tool on housing following manufacturer's instructions. Slowly spread housing no more than 0.015 inch maximum while monitoring with dial indicator. With housing spread, carefully pry carrier assembly upward and out of housing. Remove spreader immediately after carrier is out to prevent housing distortion. Place carrier on clean workbench.
5. 5

   Remove side bearing shims and record
   Carefully remove bearing races and shims from each side of carrier. Keep left and right side shims separated and labeled. Measure and record exact shim thickness for each side. These measurements are critical for reassembly preload.
6. 6

   Remove ring gear
   Mark one ring gear bolt and corresponding carrier position for rotational indexing. Remove the ring gear bolts (verify count against your carrier, typically 10 on Dana 44) using socket and breaker bar. Tap ring gear gently with plastic mallet to break it free from carrier. Remove ring gear and set aside. Note: Ring gear bolts on the Dana 44 are right-hand thread. Apply steady even force to remove.
   ℹ️Ring gear bolts may have left-hand threads. Verify thread direction before applying excessive force.
7. 7

   Disassemble differential case
   Drive out the differential pinion shaft lock pin using punch and hammer. Remove pinion shaft by sliding it out. Rotate side gears and remove differential pinion gears, noting their orientation. Remove both side gears from case.
8. 8

   Remove old clutch packs
   Remove clutch pack assemblies from each side of the differential case. Count and document the number of friction discs and steel plates in each pack. Typical configuration is 4 friction discs alternating with 4 steel plates per side, but verify against your kit. Inspect case splines for wear or damage. Clean all clutch pack seating surfaces thoroughly with solvent and shop rags.
   ℹ️Clutch disc count and orientation must match new kit specifications. Incorrect stacking will cause chatter or lock-up.
9. 9

   Install new clutch packs
   Pre-soak new clutch friction discs in 75W-90 gear oil with limited-slip additive for 15 minutes minimum. Install new clutch packs following kit instructions for proper disc sequence. Start with steel plate on case, then alternate friction disc, steel plate, friction disc, etc. Ensure splined discs engage case splines fully and tabbed plates engage side gear tabs. Install both side gears with clutch packs.
10. 10

    Reassemble differential internals
    Install both differential pinion gears in their original orientation, meshing with side gears. Rotate gears to align pinion shaft holes. Insert pinion shaft and verify free rotation of all gears. Install new pinion shaft lock pin and peen or stake in place per kit instructions. Verify all components rotate smoothly without binding.
11. 11

    Install ring gear
    Clean ring gear and carrier mating surfaces. Align ring gear with original index marks. Install ring gear bolts with medium-strength thread locker. Tighten bolts in star pattern in three stages: 25 lb-ft, 50 lb-ft, then final torque per specifications. Verify ring gear is fully seated against carrier.
    ⚠Ring gear bolts must be tightened in proper sequence to prevent ring gear distortion.
12. 12

    Install carrier bearings and shims
    Install side bearing races with original shims on each side of carrier using bearing driver. If clutch pack thickness differs from original, adjust shim thickness accordingly (thicker clutch pack requires thinner shims). Start with original shim measurements and adjust during preload check.
13. 13

    Install carrier assembly in housing
    Install differential spreader on housing and spread 0.015 inch maximum. Apply thin coat of gear oil to bearing races. Carefully lower carrier assembly into housing, ensuring bearings seat properly in races. Remove spreader immediately. Install carrier bearing caps in original positions matching punch marks. Install cap bolts finger-tight only at this stage.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
14. 14

    Adjust bearing preload and backlash
    Adjust bearing preload using selective shims (not threaded adjusters). Increase shim thickness on both sides to establish preload until all endplay is eliminated. Mount dial indicator and measure ring gear backlash. Adjust to match original measurement (0.005-0.008 inch) by loosening one adjuster and tightening the opposite side equally. Check carrier bearing preload by measuring the rolling resistance of the carrier assembly with an inch-pound torque wrench; verify against Viper service manual specification for new bearings. Once correct, tighten carrier cap bolts to specification.
    ⚠Bearing preload and backlash adjustment requires iterative adjustment. Recheck measurements after tightening cap bolts.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
15. 15

    Verify gear tooth contact pattern
    Apply thin coat of Prussian blue or gear marking compound to 6-8 ring gear teeth. Rotate pinion while applying light drag on ring gear to create contact pattern. Pattern should be centered on tooth face. If pattern is incorrect, shim adjustment is required. Coast side pattern should mirror drive side pattern.
16. 16

    Install differential cover and fill
    Clean cover and housing mating surfaces thoroughly with gasket scraper and solvent. Install new gasket with thin bead of RTV silicone on housing side. Position cover and install bolts finger-tight. Tighten cover bolts in crisscross pattern to specification. Allow RTV to cure 15 minutes. Remove fill plug from cover or housing side. Fill differential with the specified capacity of 75W-90 GL-5 gear oil (verify against Viper service manual, typically ~2.0-2.5 quarts for Dana 44). Fill until fluid reaches bottom of fill hole. Add limited-slip additive per bottle instructions (typically 4 ounces). Fill until fluid reaches bottom of fill hole. Install fill plug.
    ℹ️Limited-slip additive is mandatory for clutch-type limited-slip differentials. Omitting it will cause severe chatter and clutch damage.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
17. 17

    Install wheels and lower vehicle
    Install rear wheels and hand-tighten lug nuts. Lower vehicle to ground. Torque lug nuts to specification in star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Reassembly is covered in steps 9-17 as this procedure requires complete disassembly and rebuild.
2. Ensure all bearing caps are installed in original positions with punch marks aligned.
3. Verify backlash and bearing preload measurements match specifications before final assembly.
4. Limited-slip additive must be added to gear oil for proper clutch pack operation.

Verification

• Start engine and allow to idle. Shift through all gears to verify no abnormal noises.
• Drive vehicle in figure-eight pattern at low speed on dry pavement. Limited-slip should engage smoothly without chatter or binding.
• Check differential cover for leaks after 50 miles of driving.
• Recheck fluid level after 100 miles and top off if needed.
• Normal limited-slip operation will show slight resistance when turning in tight circles at low speed, but should not produce loud chatter or binding.
• If severe chatter occurs, drain and replace fluid ensuring proper limited-slip additive was used.

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle