Limited Slip Clutch Pack

Replace the limited slip differential clutch pack in the rear axle assembly, including disassembly of the differential carrier, inspection of components, and reassembly with proper shim selection and gear backlash setup.

Warnings

Tools required

Parts

• Limited slip clutch pack kit × 1 — Use OEM specification or quality aftermarket equivalent
• Differential cover gasket × 1 — Use OEM specification
• Pinion seal × 1 — Use OEM specification
• Axle seals × 2 — Use OEM specification
• Differential bearing shims (selection kit) × 1 — Dana rear axle shim kit
• Gear marking compound × 1 — Prussian blue or equivalent
• RTV silicone sealant × 1 — High-temperature rated
• Threadlocker (medium strength) × 1 — Loctite 243 or equivalent

Fluids

• 75W-140 synthetic GL-5 rear differential fluid — 2.75 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable
3. Raise rear of vehicle and support securely on jack stands under frame rails
4. Remove rear wheels
5. Place drain pan under differential
6. Mark driveshaft and companion flange orientation for reassembly alignment
7. Photograph or document original shim locations and thickness for reference

Procedure

1. 1

   Drain differential fluid and remove cover
   Remove the differential cover drain plug if equipped, or loosen the differential cover bolts starting from the top and working down to drain fluid into drain pan. Once drained, remove all differential cover bolts and carefully pry cover away from housing. Clean all gasket material from cover and housing mating surfaces using a plastic scraper. Inspect drained fluid for metal particles or unusual debris that may indicate additional wear.
2. 2

   Remove driveshaft
   Remove the four U-joint strap bolts at the rear differential pinion flange. Support the driveshaft and carefully slide it rearward to disengage from the transmission. Plug the transmission extension housing to prevent fluid loss. Support and secure the driveshaft out of the work area.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
3. 3

   Remove axle shafts
   Remove the differential pinion shaft lock bolt from the carrier case. Remove the pinion shaft by sliding it out of the case. Verify axle retention method for this specific Dana axle (C-clip vs. bolt-in bearing retainer). If C-clip type, push each axle shaft inward toward the center and use the C-clip tool to remove the C-clip retainers from the inner end of each axle shaft. Carefully pull both axle shafts outward and remove them from the axle housing. Keep axle shafts clean and protected during the repair.
4. 4

   Mark and remove carrier assembly
   Scribe or mark the bearing cap orientation on both sides of the carrier to ensure correct reassembly position. Remove the bearing cap bolts on both sides of the differential. The 2005 Viper uses a Dana rear axle with two bearing cap bolts per side. Carefully pry the carrier assembly upward and remove it from the axle housing. If necessary, use case spreader tool or large pry bars evenly on both sides. Place carrier assembly on clean workbench.
   ⚠Carrier assembly is heavy (approximately 40 pounds). Use proper lifting technique and have an assistant if needed.
5. 5

   Remove and document bearing preload shims
   Remove the bearing caps from the carrier case if not already separated. Carefully pry or pull the differential side bearings from the carrier case using bearing pullers. As each bearing is removed, identify and measure the shim pack behind each bearing. Record the thickness of shims on the ring gear side and pinion side separately. These measurements are critical for reassembly. Keep shims organized and labeled by location.
6. 6

   Remove ring gear from carrier
   The ring gear is bolted to the differential carrier case with 10 bolts. Apply penetrating oil to the ring gear bolts and allow to soak. Using a breaker bar and appropriate socket, remove all 10 ring gear bolts. These bolts have standard right-hand threads (verify against service manual before applying force). Tap the ring gear with a dead blow hammer to separate it from the carrier case. Set ring gear aside for inspection.
7. 7

   Disassemble differential carrier
   Remove the pinion shaft from the carrier case (if not already removed). Drive out the pinion shaft roll pin if equipped. Remove the differential pinion gears and side gears from inside the carrier case. Remove all clutch pack components, noting their orientation and order. The limited slip unit typically contains alternating friction discs and steel plates on each side. Count and document the number of friction discs and steel plates. Inspect all components for wear, scoring, or heat damage.
   ℹ️Take photos or make detailed notes of clutch pack assembly order before disassembly. Incorrect reassembly will cause improper limited slip operation.
8. 8

   Clean and inspect carrier components
   Thoroughly clean the carrier case, side gears, pinion gears, and all clutch pack components using cleaning solvent. Inspect the carrier case for cracks or damage. Check side gear and pinion gear teeth for excessive wear, pitting, or chipping. Inspect the clutch disc splines for wear. Measure clutch disc thickness and compare to service specifications. Discard any friction discs that are glazed, worn below specification, or show heat damage. Inspect steel plates for warping or scoring.
9. 9

   Install new clutch pack
   Soak new friction discs in 75W-140 synthetic GL-5 differential fluid (with limited-slip friction modifier if specified for this axle) for minimum 30 minutes before installation. Install the clutch pack components into the carrier case in the correct order as documented during disassembly. Typical order from carrier outward is: preload spring (if equipped), friction disc, steel plate, friction disc, steel plate, continuing until all components are installed. Install side gears into position. Install differential pinion gears and pinion shaft. Verify shaft alignment and install roll pin if equipped.
   ℹ️Clutch pack preload spring tension and disc count varies by application. Follow kit instructions for specific assembly sequence.
10. 10

    Install ring gear to carrier
    Clean ring gear bolt holes and apply medium-strength threadlocker to ring gear bolt threads. Position ring gear on carrier case, aligning bolt holes. Install all 10 ring gear bolts finger tight. These bolts use standard right-hand threads (verify against service manual). Tighten ring gear bolts in a star pattern to proper torque specification. After initial torque, perform a second pass to verify all bolts are properly seated.
11. 11

    Install carrier bearings and initial shim selection
    Install the original shim packs on each side of the carrier case as documented during disassembly. Press or drive the differential side bearings onto the carrier case using appropriate bearing installation tools or hydraulic press. Ensure bearings are fully seated against the shim packs. If new bearings are being installed, start with shims 0.003-0.005 inch thicker than original to account for new bearing crush.
12. 12

    Install carrier assembly and set bearing preload
    Carefully lower the carrier assembly into the axle housing, aligning the bearing caps with their original scribed marks. Install bearing caps in their original orientation. Install bearing cap bolts finger tight. Using a dial indicator on the ring gear, measure side-to-side end play. Adjust shim thickness to achieve zero end play, then add shims to create proper bearing preload. Proper preload typically requires 0.004-0.008 inch additional shim thickness beyond zero end play. Tighten bearing cap bolts to proper specification in multiple passes.
13. 13

    Check and adjust ring gear backlash
    Mount a dial indicator with the plunger contacting a ring gear tooth at 90 degrees to the tooth face. Rock the ring gear back and forth while holding the pinion flange stationary. Measure backlash at four equally spaced points around the ring gear. Backlash should be 0.005-0.009 inch and should not vary more than 0.002 inch around the gear. If backlash is incorrect, transfer shims from one side to the other (moving shims from right to left increases backlash; left to right decreases backlash). Maintain total shim thickness to preserve bearing preload.
    ℹ️Proper backlash is critical for gear noise and longevity. Take time to achieve specification.
14. 14

    Verify gear contact pattern
    Apply gear marking compound to several ring gear teeth. Rotate the pinion through several complete revolutions in both directions while applying moderate resistance to the ring gear. Remove carrier and inspect tooth contact pattern on the ring gear. Proper contact pattern should be centered on the tooth face with even distribution. If pattern is incorrect, adjust pinion depth shims and carrier shims as necessary. This may require removing and reinstalling the carrier assembly multiple times.
    ⚠Incorrect gear contact pattern will cause noise and premature wear. Pattern must be verified before final assembly.
15. 15

    Final carrier installation and axle shaft installation
    Once bearing preload, backlash, and tooth contact are verified correct, perform final carrier installation. Torque bearing cap bolts to specification in a crossing pattern. Install axle shafts into the axle housing, engaging the splines with the side gears. Push each axle shaft inward and install the C-clip retainer on the inner end of each shaft. Pull axle shafts outward to seat the C-clips. Install the pinion shaft through the carrier case and differential gears. Install and torque the pinion shaft lock bolt to specification.
16. 16

    Install driveshaft
    Remove the plug from the transmission extension housing. Align the driveshaft with reference marks made during disassembly. Slide the driveshaft forward into the transmission. Align the rear U-joint with the pinion flange and install the U-joint straps and bolts. Torque strap bolts evenly to specification.
    Torque spec

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)
17. 17

    Install differential cover and fill with fluid
    Clean all RTV residue from the differential cover and housing mating surfaces. Apply a continuous bead of RTV silicone gasket maker to the differential cover or install new gasket if using pre-formed gasket. Install differential cover and bolts. Torque cover bolts in a crossing pattern to specification. Allow RTV to cure per manufacturer instructions (typically 1 hour) before filling. Fill differential with 75W-140 synthetic GL-5 differential fluid (verify capacity against service manual, approximately 2.75 quarts) through the fill plug opening until fluid reaches the bottom of the fill plug hole. Install and tighten fill plug.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
18. 18

    Reinstall wheels and perform final checks
    Install rear wheels and torque lug nuts to specification in a star pattern. Lower vehicle from jack stands. Reconnect negative battery cable. Test drive vehicle and verify proper limited slip operation, checking for unusual noise, vibration, or handling issues. Monitor for fluid leaks during the first 100 miles of operation.
    Torque spec

    Wheel Lug Nuts142.4 Nm (105 lb-ft)

Reassembly

1. Reassembly follows disassembly steps in reverse order with critical attention to bearing preload and gear backlash specifications
2. All measurements must be verified before final assembly
3. Use new gaskets and seals throughout
4. Allow RTV sealant to cure before filling with fluid
5. Break in new clutch pack by avoiding aggressive launches for the first 100 miles

Verification

• Check for fluid leaks at differential cover, pinion seal, and axle seals after test drive
• Verify proper limited slip operation by performing slow turns - both wheels should drive together with slight tire scrubbing
• Confirm no abnormal noise from differential under load or deceleration
• Verify differential fluid level is at bottom of fill plug hole after vehicle has cooled
• Re-torque differential cover bolts after 50 miles if any seepage is observed

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