Replace the limited slip differential clutch pack in the rear axle to restore proper traction performance.

Warnings

Tools required

Parts

• Limited slip clutch pack kit × 1 — Use OEM specification for Dana 44 rear axle
• Differential cover gasket or RTV sealant × 1 — Mopar RTV or equivalent
• Differential bearing shims (if required) × 1 — Use OEM specification
• Gear marking compound × 1 — Standard differential setup compound
• Limited slip additive × 1 — Mopar friction modifier

Fluids

• Mopar 75W-140 Synthetic Gear Lubricant — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen rear wheel lug nuts while vehicle is on ground
3. Raise rear of vehicle and support securely on jack stands at frame rails
4. Remove rear wheels
5. Place drain pan under differential
6. Allow differential to cool if recently driven (gear oil retains heat)

Procedure

1. 1

   Remove driveshaft
   Mark relationship between driveshaft and pinion flange for reinstallation. Remove the four driveshaft bolts at the rear differential yoke. Support driveshaft and pull rearward to separate from pinion flange. Secure driveshaft out of the way or remove completely.
   Torque spec

   Driveshaft Bolts85 Nm (63 lb-ft)
2. 2

   Drain differential fluid
   Remove all differential cover bolts and carefully pry cover away from housing. Allow gear oil to drain completely into drain pan. Inspect drained fluid for excessive metal particles or debris which may indicate additional damage. Remove and discard old gasket material or RTV from cover and housing mating surfaces.
   Torque spec

   Differential Cover Bolts39 Nm (29 lb-ft)
3. 3

   Mark bearing caps and measure backlash
   Mark the differential bearing caps with punch marks to ensure correct reinstallation orientation. Install dial indicator on ring gear and measure existing backlash at multiple teeth positions. Record these measurements for reference during reassembly. Remove bearing cap bolts and carefully remove bearing caps.
4. 4

   Remove differential assembly
   Carefully pry differential case assembly out of the housing using pry bars at both bearing locations. Keep bearing races and shims organized by side (left/right) as they must return to original positions if reused. Place differential assembly on clean work surface.
5. 5

   Disassemble differential case
   Remove ring gear bolts and separate ring gear from differential case (if required for access). Drive out differential pinion shaft retaining pin. Remove pinion shaft, pinion gears, side gears, and thrust washers. Keep all components organized in order of removal.
   ⚠Pinion shaft retaining pin is under spring tension. Control pin during removal to prevent loss.
6. 6

   Remove old clutch packs
   Remove the old limited slip clutch packs from both sides of the differential case. Note the orientation and order of friction discs and steel plates. Clean all clutch pack surfaces in the differential case thoroughly with solvent and dry completely. Inspect case for scoring or damage.
7. 7

   Install new clutch packs
   Soak new friction discs in Mopar 75W-140 gear oil for 20-30 minutes before installation. Install new clutch packs in the correct order per manufacturer instructions, alternating friction discs and steel plates. Ensure proper orientation with tabs engaging case slots. Install side gears with thrust washers onto clutch packs.
   ℹ️Clutch pack assembly order is critical. Refer to clutch pack kit instructions for specific stacking sequence.
8. 8

   Reassemble differential internals
   Install pinion gears and align with side gears. Rotate side gears to align pinion gear holes. Install pinion shaft through case and gears. Verify all gears rotate smoothly. Install new pinion shaft retaining pin and seat fully. Reinstall ring gear (if removed) with new bolts torqued to specification in crossing pattern.
9. 9

   Install differential assembly
   Install original shims on differential bearings. Carefully install differential assembly back into axle housing, seating bearings into their bores. Install bearing caps in original orientation per punch marks. Hand-tighten bearing cap bolts. Use differential spreader to ensure case seats properly, then torque bearing cap bolts per service manual specification.
   ⚠Do not over-spread differential housing. Maximum spread is typically 0.015 inches. Excessive spreading can crack housing.
10. 10

    Check and adjust backlash
    Install dial indicator on ring gear and check backlash at multiple teeth positions. Backlash should be 0.005-0.009 inches. If backlash is incorrect, adjust by moving shims from one side to the other (moving shims toward ring gear decreases backlash, away increases it). Recheck backlash after any shim adjustment.
11. 11

    Verify gear pattern
    Apply gear marking compound to several ring gear teeth. Rotate pinion in both directions under light resistance to create contact pattern. Inspect pattern on coast and drive sides. Pattern should be centered on tooth face. Adjust shimming if pattern is incorrect. This step requires experience with differential setup.
    ℹ️Proper gear pattern is critical for differential longevity. If unfamiliar with pattern reading, consult professional or service manual diagrams.
12. 12

    Clean and install differential cover
    Clean differential cover and housing mating surfaces thoroughly with solvent. Remove all old gasket material and RTV. Apply continuous 1/8-inch bead of Mopar-approved RTV sealant to cover or housing surface. Install cover within 10 minutes of RTV application. Install all cover bolts and torque in crossing pattern.
    ℹ️Allow RTV to cure for minimum 1 hour before filling with fluid per sealant manufacturer instructions.
    Torque spec

    Differential Cover Bolts39 Nm (29 lb-ft)
13. 13

    Reinstall driveshaft
    Align driveshaft to pinion flange using marks made during removal. Install driveshaft bolts and torque to specification in crossing pattern. Ensure U-joint caps are properly seated in yoke.
    Torque spec

    Driveshaft Bolts85 Nm (63 lb-ft)
14. 14

    Fill differential with fluid
    Remove differential fill plug. Fill differential with Mopar 75W-140 Synthetic Gear Lubricant until fluid reaches bottom of fill hole (approximately 2.0 quarts). Add appropriate amount of limited slip additive per bottle instructions. Reinstall fill plug. Wipe exterior clean.
15. 15

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

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Double-check all fasteners are torqued to specification
2. Verify no tools or parts are left in work area or under vehicle
3. Check differential cover for leaks after 24 hours
4. Recheck fluid level after test drive

Verification

• Start engine and verify no unusual noises from rear differential
• Test drive vehicle in safe area, making gentle turns in both directions
• Limited slip function should engage smoothly during turns without chattering
• Recheck differential cover for leaks after test drive
• Verify fluid level at fill plug after vehicle has sat level for 10 minutes
• Monitor differential performance over next 100 miles; slight break-in chatter is normal and should diminish

More procedures for this vehicle