Limited Slip Clutch Pack

Replace the limited slip differential clutch pack in the rear differential, restoring proper traction control functionality.

Warnings

Tools required

Parts

• Limited slip clutch pack kit × 1 — Use OEM Mopar AAM 11.5" clutch pack
• Differential cover gasket × 1 — Use OEM specification
• Carrier bearing shims (assorted) × 1 — Use OEM specification
• Pinion seal × 1 — Use OEM specification
• Differential side seals × 2 — Use OEM specification
• Friction modifier additive × 1 — Mopar limited slip additive

Fluids

• Mopar 75W-140 Synthetic Gear Lubricant — 2.5 qt

Preparation

1. Park vehicle on level surface and chock front wheels securely
2. Raise rear of vehicle and support on jack stands at frame rails behind rear axle
3. Remove both rear wheels
4. Place drain pan under differential cover
5. Mark driveshaft and pinion flange orientation for reinstallation alignment

Procedure

1. 1

   Drain differential and remove cover
   Remove all differential cover bolts and allow gear oil to drain completely into pan. Remove cover and gasket material. Clean mating surfaces thoroughly with brake cleaner. Inspect drained oil for metal particles indicating additional wear.
   Torque spec

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

   Remove driveshaft
   Remove the four U-joint strap bolts securing driveshaft to pinion flange. Support driveshaft and slide rearward off transmission output shaft. Secure driveshaft out of work area. Stuff clean rag in transmission extension housing to prevent fluid loss.
   Torque spec

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

   Mark and measure carrier bearing preload
   Using dial indicator, measure and record pinion rotating torque and carrier bearing preload. Mark carrier bearing caps with punch marks for orientation. These measurements are critical for reassembly. Note position of all shims behind carrier bearings.
   ℹ️Record all measurements precisely. These are baseline values for reassembly verification.
4. 4

   Install differential spreader
   Install differential spreader tool according to manufacturer instructions, mounting to case spreader bolt holes. Install dial indicator to measure case spread. Carefully spread case a maximum of 0.010-0.015" to allow carrier removal. Do not exceed 0.015" or permanent case damage will occur.
   ⚠️Monitor dial indicator continuously. Exceeding 0.015" spread will permanently distort the differential case.
5. 5

   Remove carrier bearing caps and carrier assembly
   With case spread, remove carrier bearing cap bolts. Remove bearing caps using pry bars if necessary, keeping them matched to their original sides. Carefully pry carrier assembly upward and remove from case. Remove and keep all shims organized by side, marking clearly for reinstallation.
   ⚠Carrier assembly is heavy (approximately 40 lbs). Use proper lifting technique.
6. 6

   Disassemble carrier and remove clutch pack
   Place carrier assembly on clean workbench. Remove carrier cross shaft lock bolt. Drive out cross shaft using brass punch. Remove pinion gears and side gears. Carefully remove clutch pack assemblies from both sides, keeping clutches and shims organized by side. Count and record number of friction discs and steel plates. Measure clutch pack thickness with micrometer for each side.
   ℹ️Take detailed notes and photos of clutch pack orientation, shim placement, and tab alignment. This is critical for correct reassembly.
7. 7

   Clean and inspect carrier components
   Thoroughly clean all carrier components with brake cleaner. Inspect side gear splines, pinion gear teeth, and carrier case for wear or damage. Inspect spider gear cross shaft bore for wear. Replace any worn components. Clean carrier bearing races and inspect for pitting or scoring.
   ⚠Even minor scoring on gear teeth indicates the need for replacement. Do not reuse damaged gears.
8. 8

   Install new clutch pack
   Soak new clutch friction discs in 75W-140 gear oil for 20 minutes before installation. Install new clutch packs following exact sequence from OEM kit instructions: typically alternating friction disc, steel plate, ensuring tabs engage properly in side gear and case. Install clutch packs on both sides with correct shims. Verify clutch pack height matches original measurements within 0.005".
   ℹ️Clutch disc tabs must align correctly in case and gear slots. Incorrect installation will cause immediate failure.
9. 9

   Reassemble carrier
   Install side gears with clutch packs into carrier. Install pinion gears and rotate to align cross shaft holes. Install cross shaft, ensuring lock bolt hole aligns properly. Install and torque cross shaft lock bolt per service manual specification (typically 20-25 lb-ft). Verify smooth rotation of side gears.
   ⚠Cross shaft lock bolt must be properly torqued and may require thread locker per OEM specification.
10. 10

    Install carrier assembly
    Lubricate carrier bearings with gear oil. Install original shims on carrier bearing races in exact original positions. Spread differential case 0.010-0.015" using spreader tool. Install carrier assembly into case, seating bearings into races. Install bearing caps in original orientation, ensuring punch marks align. Release spreader tool slowly.
    Torque spec

    Mounting Bolts37 Nm (27 lb-ft)
11. 11

    Set bearing preload and backlash
    Install carrier bearing cap bolts and torque to specification. Check ring gear backlash with dial indicator at multiple points around ring gear; should be 0.004-0.009". Adjust by moving shims from one side to other as needed. Verify pinion rotating torque matches original baseline measurement plus 3-5 inch-pounds for new clutches. Apply gear marking compound and check tooth contact pattern.
    ℹ️Backlash adjustment requires patience. Move shims in pairs from side to side to maintain bearing preload while adjusting backlash.
    Torque spec

    Mounting Bolts37 Nm (27 lb-ft)
12. 12

    Reinstall driveshaft
    Remove rag from transmission extension housing. Align driveshaft with pinion flange using original alignment marks. Install U-joint strap bolts and torque evenly in crisscross pattern to specification.
    Torque spec

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)
13. 13

    Install differential cover and fill
    Apply 1/4" bead of RTV silicone to differential cover mating surface. Install new gasket if using. Install cover and bolts, torquing in crisscross pattern to specification. Allow RTV to cure for 1 hour before filling. Fill differential with 2.0 quarts Mopar 75W-140 synthetic gear lubricant plus 4 oz limited slip friction modifier additive. Install fill plug.
    ℹ️Limited slip friction modifier is essential for proper clutch pack operation and must be added.
    Torque spec

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

    Reinstall wheels and test
    Install rear wheels and torque lug nuts in star pattern to specification. Lower vehicle to ground. Test drive vehicle, making multiple figure-8 turns in both directions to allow clutches to seat properly. Listen for chattering or unusual noises indicating improper assembly.
    ⚠Some limited slip clutch chatter during initial break-in is normal but should diminish after 50-100 miles.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Apply thread locker to all fasteners as specified in service manual
2. Ensure all bearing caps and shims are installed in original positions
3. Verify gear tooth contact pattern is correct before final assembly
4. Allow RTV sealant to cure fully before filling with gear oil

Verification

• Check differential cover for leaks after test drive
• Verify smooth operation with no chattering during tight turns
• Confirm both rear wheels provide equal traction when tested on slippery surface
• Recheck differential fluid level after 50 miles and top off if needed
• Listen for abnormal noise during normal driving and tight turning maneuvers

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