Limited Slip Clutch Pack

Replace the limited slip clutch pack in the rear differential of a 2008 Dodge Viper, including draining and refilling with synthetic gear oil.

Warnings

Tools required

Parts

• Limited slip clutch pack kit × 1 — Use OEM specification
• Differential cover gasket × 1 — Use OEM specification
• Pinion shaft lock bolt × 1 — Use OEM specification
• Crush washer for differential fill plug × 1 — Use OEM specification if reusable seal is damaged

Fluids

• 75W-90 synthetic gear oil (rear differential) — 2.75 qt

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Chock the front wheels securely.
3. Raise rear of vehicle with floor jack and support on jack stands at manufacturer-recommended lift points on rear subframe or axle housing.
4. Ensure vehicle is stable and level before working underneath.
5. Allow differential to cool if vehicle was recently operated.
6. Clean exterior of differential housing and cover area to prevent contamination during service.

Procedure

1. 1

   Drain differential fluid
   Position drain pan under differential cover. Remove the differential cover bolts in a crisscross pattern, loosening the top bolts last to allow fluid to drain in a controlled manner. Once fluid begins draining, remove remaining bolts and carefully remove the cover. Allow fluid to drain completely. Inspect drained fluid for excessive metal debris, which may indicate bearing or gear wear requiring further inspection.
2. 2

   Remove pinion shaft and cross pin
   Locate the pinion shaft lock bolt on the differential case (accessible through the differential cover opening). Remove the pinion shaft lock bolt. Using a punch or drift and soft-face hammer, carefully drive the pinion shaft out of the differential case. Remove the pinion shaft and set aside. Note: The pinion shaft passes through the spider gears and cross pin.
3. 3

   Remove spider gears and side gears
   Rotate the axle shafts to align the spider gears with the opening in the differential case. Remove both spider gears and their thrust washers through the opening. Remove both side gears from each side of the carrier, noting the orientation and position of any shims or thrust washers behind each side gear. Keep all shims and washers organized by position for reassembly.
4. 4

   Remove clutch pack assembly
   With side gears removed, the limited slip clutch packs will be accessible on each side of the differential carrier. Remove the clutch disc stack from one side, keeping discs in order. The pack will consist of alternating friction discs (splined internally to the side gear) and steel plates (tabbed externally to the differential case). Count and record the number and sequence of discs. Note the position and thickness of any preload shims or wave springs. Repeat for the opposite side clutch pack. Measure and record shim thickness with calipers if preload shims are present.
5. 5

   Clean and inspect differential internals
   Thoroughly clean the inside of the differential carrier, clutch pack mounting surfaces, and all gear components with parts cleaning solvent. Inspect the differential case clutch pack mounting surfaces for scoring, wear, or damage. Inspect side gear splines and thrust surfaces for wear. Inspect spider gear teeth and thrust surfaces. Replace any components showing excessive wear or damage.
6. 6

   Install new clutch packs
   Install the new clutch pack on one side of the differential carrier following the sequence specified in the clutch pack kit instructions (typically alternating friction disc and steel plate). Install any preload shims or wave springs in their original positions with original thickness measurements. If new shims are provided in the kit, use those per kit instructions. Ensure friction discs are oriented correctly with friction material facing the proper direction. Repeat installation for the opposite side clutch pack, ensuring symmetrical assembly.
7. 7

   Install side gears and spider gears
   Install the side gears into the differential carrier, engaging them with the clutch pack internal splines. Install the original thrust washers and shims behind each side gear in their original positions. Install the spider gears and their thrust washers into the carrier, rotating the axle shafts as necessary to align components. Ensure spider gears mesh properly with both side gears.
8. 8

   Install pinion shaft and lock bolt
   Align the spider gears to accept the pinion shaft. Insert the pinion shaft through the differential case and spider gears, ensuring it passes through completely and aligns with the lock bolt hole. Install the new pinion shaft lock bolt and tighten to specification. Rotate the axle shafts by hand to verify smooth operation and proper clutch pack engagement (some resistance is normal with limited slip differentials).
9. 9

   Prepare and install differential cover
   Clean the differential cover and carrier housing mating surfaces thoroughly, removing all old gasket material. If using a gasket, position the new gasket on the cover. If using RTV silicone, apply a continuous 1/8-inch bead of RTV to the cover mating surface, circling all bolt holes on the inside. Position the cover onto the differential carrier and install all cover bolts finger-tight.
10. 10

    Torque differential cover bolts
    Tighten the differential cover bolts in a crisscross pattern to proper specification (consult factory service manual for exact torque value, typically 15-20 ft-lb for these applications). Make multiple passes, gradually increasing torque to final specification to ensure even gasket compression. If RTV was used, allow to cure per manufacturer's instructions before filling.
11. 11

    Refill differential with gear oil
    Locate the differential fill plug on the front or side of the differential housing. Remove the fill plug. Using a fluid pump or fill bottle with hose, add 75W-90 synthetic gear oil through the fill hole until fluid reaches the bottom of the fill plug hole (fluid should just begin to seep out). Install the fill plug with new crush washer if equipped and tighten to specification. Wipe away any spilled fluid.
12. 12

    Lower vehicle and perform initial test
    Remove jack stands and carefully lower the vehicle to the ground. Start the engine and allow to idle. With the parking brake engaged, shift the transmission through all gears to circulate fluid through the differential. Test drive the vehicle in a safe area, making gentle turns in both directions to verify proper limited slip operation. Listen for any abnormal noises from the differential.

Reassembly

1. Torque all fasteners to manufacturer specifications using a calibrated torque wrench.
2. If using RTV silicone instead of a gasket, allow proper cure time (typically 1 hour minimum) before filling with fluid.
3. Ensure clutch pack discs are installed in the correct sequence per the kit instructions, with friction discs and steel plates alternating properly.
4. Verify pinion shaft lock bolt is properly torqued and secured to prevent shaft migration.
5. Check differential fluid level after initial test drive and top off if necessary.

Verification

• Check for fluid leaks around the differential cover after initial test drive.
• Verify smooth operation during straight-line acceleration with no abnormal noise or vibration.
• Confirm limited slip function by performing a controlled low-speed turn on dry pavement; both rear wheels should drive with slight resistance (chirping is normal).
• Recheck differential fluid level after 50-100 miles of driving and top off if needed.
• Monitor for any abnormal differential noise, vibration, or handling characteristics during the first 500 miles.

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