Limited Slip Clutch Pack

Replace the limited slip differential clutch pack assembly in the rear differential, requiring differential removal, disassembly, clutch pack replacement, and reassembly with proper shimming and preload adjustment.

Warnings

Tools required

Parts

• Limited slip clutch pack kit × 1 — Use OEM Maserati specification
• Differential cover gasket × 1 — Use OEM specification
• Differential pinion seal × 1 — Use OEM specification
• Side bearing shims (assorted) × 1 — Selection kit required for proper setup
• Differential carrier bearing set × 1 — Replace if wear evident
• Pinion bearing set × 1 — Replace if wear evident
• Ring gear bolts × 1 — Use OEM one-time-use bolts
• Shop towels × 1 — For cleanup

Fluids

• 75W-140 Synthetic Gear Oil — 2.5 qt

Preparation

1. Park vehicle on level ground and set parking brake
2. Lift vehicle and secure on jack stands at manufacturer-specified lift points
3. Remove rear wheels and set aside
4. Place drain pan under differential
5. Allow differential to cool if vehicle was recently operated
6. Document driveline orientation with paint marks for reassembly reference
7. Photograph differential setup before disassembly for reference

Procedure

1. 1

   Remove rear axle shafts
   Remove wheel speed sensors from axle shafts. Remove CV joint bolts connecting inner CV joints to differential stub axles. Carefully pull axle shafts out and support them with wire or zip ties to prevent damage to outer CV boots. Do not let axles hang by CV joints.
   Torque spec

   CV Joint Bolts64 Nm (47 lb-ft)
2. 2

   Disconnect driveshaft
   Mark driveshaft-to-differential flange orientation with paint. Remove driveshaft bolts at differential flange. Support driveshaft and carefully lower or slide forward. Secure driveshaft out of work area. Insert plug into transmission tailshaft to prevent fluid loss if applicable.
   Torque spec

   Driveshaft Bolts79 Nm (58 lb-ft)
3. 3

   Drain differential and remove cover
   Remove differential cover bolts starting from bottom to allow fluid to drain into pan. Once drained, remove remaining bolts and cover. Clean all gasket material from cover and housing mating surfaces using scraper. Inspect internal components for metal debris or damage. Remove and discard old gasket.
   ⚠Differential fluid will drain quickly once bottom bolts are removed. Ensure drain pan is properly positioned.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
4. 4

   Remove differential carrier assembly
   Remove carrier bearing cap bolts. Mark bearing caps with their positions (left/right orientation). Carefully pry carrier assembly out of housing using appropriate pry points. Remove carrier with ring gear attached as a complete assembly. Place carrier in padded vice or holding fixture for disassembly.
   Torque spec

   Mounting Bolts28 Nm (21 lb-ft)
5. 5

   Disassemble carrier and document setup
   Measure and record ring gear backlash at multiple points around ring gear using dial indicator. Measure and record bearing preload. Remove side bearing races using bearing puller. Keep all shims with their respective bearings and label them clearly. Remove ring gear bolts and separate ring gear from carrier. Note rotational direction marking on ring gear.
   ℹ️Original shim measurements are critical for reassembly starting point. Label all shims clearly with their original positions.
6. 6

   Remove differential cross pin and internals
   Remove cross pin retaining bolt if equipped. Drive out cross pin using appropriate punch. Rotate side gears and remove pinion gears, side gears, and thrust washers. Keep all components organized and inspect for wear. Remove old limited slip clutch packs from carrier, noting their orientation and order of assembly.
   ℹ️Photograph clutch pack arrangement before removal. Clutch pack orientation and sequence is critical for proper operation.
7. 7

   Clean and inspect components
   Thoroughly clean carrier, side gears, pinion gears, and cross pin with solvent. Inspect all gear teeth for chips, cracks, or excessive wear. Inspect carrier bearing bores for damage. Measure side gear and pinion gear clearances. Replace any worn components. Clean ring gear and inspect for damage.
   ⚠Any components showing wear, scoring, or damage must be replaced. Reusing worn parts will cause premature failure.
8. 8

   Prepare and install new clutch packs
   Soak new limited slip clutch packs in 75W-140 synthetic gear oil for minimum 20 minutes before installation. Install clutch packs in carrier in correct sequence per manufacturer specifications, alternating friction and steel plates. Install side gears with thrust washers, ensuring proper orientation. Check that side gear rotation requires appropriate effort indicating clutch pack engagement.
   ⚠Clutch plates must be fully saturated with gear oil before installation to prevent initial break-in damage.
9. 9

   Install pinion gears and cross pin
   Install pinion gears with thrust washers into carrier, meshing with both side gears. Rotate gears to align cross pin holes. Install cross pin through carrier and pinion gears. Verify cross pin retaining bolt hole alignment. Install and tighten cross pin retaining bolt with thread locker per specification. Verify smooth rotation of side gears with appropriate limited slip resistance.
   ℹ️Apply medium-strength thread locker to cross pin retaining bolt to prevent loosening during operation.
10. 10

    Install ring gear and bearing races
    Clean ring gear bolt holes and apply thread locker to new ring gear bolts. Install ring gear to carrier in original orientation, aligning bolt holes. Install new ring gear bolts and torque in star pattern to specification. Press or drive new bearing races onto carrier using appropriate bearing driver, ensuring full seating. Install original shims as starting point for setup.
    ⚠Ring gear bolts are one-time-use and must be replaced. Torque in multiple steps using star pattern.
11. 11

    Install carrier and check backlash
    Install carrier assembly with bearing races and shims into housing. Install bearing caps in original positions (note markings). Torque bearing cap bolts gradually in cross pattern. Mount dial indicator to housing with plunger on ring gear tooth. Check backlash at multiple points around ring gear. Backlash should be 0.13-0.20mm (0.005-0.008 inch). Adjust shims as necessary to achieve specification.
    ℹ️Backlash adjustment requires moving shims from one side to the other. Moving shim from right to left decreases backlash.
    Torque spec

    Mounting Bolts28 Nm (21 lb-ft)
12. 12

    Verify gear pattern and preload
    Apply gear marking compound to several ring gear teeth. Rotate pinion in both directions while applying resistance. Inspect contact pattern on ring gear teeth. Pattern should be centered on tooth face. Adjust shims if pattern is incorrect. Measure bearing preload using inch-pound torque wrench. Preload should be 1.1-1.7 Nm (10-15 inch-pounds) for used bearings. Adjust shim thickness to achieve proper preload.
    ⚠Incorrect gear pattern will cause noise and premature wear. Pattern must be corrected before final assembly.
13. 13

    Install differential cover
    Clean cover and housing mating surfaces thoroughly. Apply thin bead of RTV gasket maker to cover or install new gasket per manufacturer specification. Install cover and insert all bolts finger-tight. Torque cover bolts in cross pattern to specification. Allow RTV to cure per product instructions before filling with fluid.
    ℹ️Do not over-apply RTV as excess can contaminate differential and block passages. Bead should be 2-3mm wide.
    Torque spec

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

    Reconnect driveshaft and axles
    Clean driveshaft flange and differential flange mating surfaces. Align driveshaft to differential flange using reference marks made during disassembly. Install driveshaft bolts and torque to specification. Reconnect CV joints to stub axles, ensuring proper alignment. Install CV joint bolts and torque to specification. Reinstall wheel speed sensors.
    Torque spec

    Driveshaft Bolts79 Nm (58 lb-ft)

    CV Joint Bolts64 Nm (47 lb-ft)
15. 15

    Fill differential with fluid
    Remove differential fill plug. Using fluid pump or squeeze bottle, fill differential with 75W-140 synthetic gear oil until fluid reaches bottom of fill hole (approximately 2 quarts). Allow fluid to stabilize for 2-3 minutes and top off if necessary. Install fill plug with new washer if equipped and torque to specification. Wipe clean any spilled fluid.
    ℹ️Limited slip differentials require specific gear oil with limited slip additive or friction modifier. Use only specified 75W-140 synthetic gear oil.

Reassembly

1. Install rear wheels and torque lug nuts in star pattern to specification
2. Lower vehicle from jack stands to ground
3. Perform final torque verification on all fasteners after vehicle weight is on suspension
4. Dispose of used differential fluid according to local environmental regulations

Verification

• Start vehicle and verify no unusual noises from differential
• Test drive vehicle at low speed in safe area, making gradual turns in both directions
• Listen for clunking, whining, or grinding noises indicating improper setup
• Verify limited slip operation by performing slow-speed tight turn - mild chatter is normal for clutch-type limited slip
• Inspect differential cover and all connections for fluid leaks after test drive
• Re-check differential fluid level after test drive and top off if necessary
• Verify no vibration or abnormal drivetrain behavior at highway speeds
• Check fluid level again after 100 miles of driving and inspect for leaks

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