Limited Slip Clutch Pack

This procedure covers removal and replacement of the limited slip clutch pack in the rear differential of a 2007 Ram 3500 4WD with the 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Limited slip clutch pack kit (includes clutch discs and plates) × 1 — Use OEM specification or equivalent Trac-Lok kit
• Differential cover gasket × 1 — Use OEM specification
• Pinion shaft lock pin × 1 — Use OEM specification
• Gear marking compound × 1 — Use OEM specification
• Differential friction modifier additive × 1 — Mopar limited slip additive or equivalent

Fluids

• 75W-90 synthetic gear oil — 5.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks in front of front wheels
3. Raise rear of vehicle and support securely on jack stands under frame rails
4. Remove both rear wheels
5. Allow differential to cool completely if vehicle was recently driven
6. Position catch pan under rear differential

Procedure

1. 1

   Drain differential and remove cover
   Remove all differential cover bolts using 13mm socket. Carefully pry cover away from housing using a flat blade screwdriver, allowing gear oil to drain into catch pan. Once drained, remove cover completely and set aside. Clean the inside of the differential housing and cover mating surface thoroughly with parts cleaner.
2. 2

   Mark and document existing setup
   Before disassembly, use paint marker to mark the bearing caps in relation to the differential housing for proper reinstallation. Take note of any shims present and their locations. If possible, measure and record pinion bearing preload and ring gear backlash for reference during reassembly.
3. 3

   Remove pinion shaft and axle shafts
   Locate the cross (mate) shaft retainer on the differential case. On the AAM 11.5 axle this is typically a retaining bolt/roll pin — verify against the factory service manual, remove the retainer, then withdraw the cross shaft from the carrier. The AAM 11.5-inch full-floating rear axle does not use C-clip axle retention. Remove the axle shaft retaining bolts/nuts at the axle flange and withdraw each axle shaft from the housing to provide clearance for carrier removal.
4. 4

   Remove bearing caps and carrier assembly
   Remove the bolts securing both side bearing caps using appropriate socket. Note that bearing caps are line-bored to their specific positions and must be reinstalled in the exact same location and orientation; reference your paint marks. Carefully remove both bearing caps. Using a pry bar or differential spreader if available, carefully pry the carrier assembly out of the housing. The carrier assembly includes the ring gear, side gears, spider gears, and limited slip clutch packs.
5. 5

   Disassemble carrier and remove old clutch packs
   Place carrier assembly on a clean workbench with ring gear facing down. Remove the ring gear bolts if necessary to access clutch packs (not always required depending on differential design). Carefully separate the carrier halves. Remove and inspect the spider gears, side gears, thrust washers, and existing clutch packs. Note the order and orientation of all clutch discs and plates as you remove them. Count the number of friction discs and steel plates. Clean all components thoroughly with parts cleaner.
6. 6

   Inspect components and prepare new clutch packs
   Inspect all spider gears, side gears, and thrust washers for wear, pitting, or damage. Replace if necessary. Inspect carrier case and ring gear for cracks or damage. Verify new clutch pack components match the original configuration. Soak new friction discs in 75W-90 gear oil for at least 15 minutes before installation.
7. 7

   Install new clutch packs
   Install new clutch packs in the correct order, alternating between friction discs and steel plates. Typical arrangement starts with a steel plate, then friction disc, continuing to alternate. Ensure discs are fully seated and oriented correctly. Install side gears with new clutch packs on both sides of the carrier. Install thrust washers in their original positions.
8. 8

   Reassemble carrier assembly
   Install spider gears into the carrier with thrust washers in place. Align the carrier halves and carefully bring them together, ensuring all gears mesh properly. If ring gear was removed, clean threads with thread cleaner and apply blue thread locker to ring gear bolts. Install and tighten ring gear bolts in a star pattern. Note: Without torque specifications in database, refer to factory service manual for proper torque values.
9. 9

   Install carrier assembly into housing
   Carefully install the carrier assembly back into the differential housing, aligning the side bearing races. If original shims were present, install them in their original locations. Install bearing caps in their original positions according to your paint marks. Start all bearing cap bolts by hand, then tighten in a cross pattern. Note: Without torque specifications in database, refer to factory service manual for proper torque values.
10. 10

    Verify gear pattern and backlash
    If dial indicator is available, check ring gear backlash at 4 points around the ring gear. Backlash should be set to the factory-specified value for the AAM 11.5 axle (verify in factory service manual, typically approximately 0.005-0.010 inches). Apply gear marking compound to several ring gear teeth. Rotate pinion gear through several revolutions while applying light resistance to the ring gear. Inspect tooth contact pattern; it should be centered on the teeth. Adjust shims if necessary to achieve proper pattern.
11. 11

    Reinstall pinion shaft and axle C-clips
    Slide the pinion shaft back through the carrier and spider gears, ensuring it is fully seated. Reinstall each axle shaft into the housing, engaging the splines, and reinstall the axle flange retaining bolts/nuts to factory torque. This full-floating axle does not use C-clip retention. Align the pinion shaft lock pin hole and install new lock pin, driving it flush with the carrier surface.
12. 12

    Install differential cover
    Clean all old gasket material from the differential housing mating surface using gasket scraper. Ensure surface is completely clean and dry. Apply a thin bead of RTV silicone to the housing mating surface or install new gasket per gasket manufacturer instructions. Position differential cover and install all bolts finger tight. Tighten cover bolts in a star pattern to ensure even sealing. Note: Without torque specifications in database, refer to factory service manual for proper torque values. Allow RTV to cure for at least 15 minutes before filling.
13. 13

    Fill differential with gear oil and additive
    Locate the differential fill plug on the front of the housing. Remove fill plug. Using a gear oil pump, fill the differential with approximately 3.5 quarts of the OEM-specified synthetic gear oil (verify 75W-90 vs 75W-140 in the factory service manual) mixed with the appropriate amount of limited slip friction modifier additive per additive bottle instructions. Fill until oil reaches the bottom of the fill plug hole. Install and tighten fill plug. Wipe away any spilled oil.
14. 14

    Reinstall wheels and lower vehicle
    Install both rear wheels and hand tighten lug nuts in a star pattern. Lower vehicle until wheels just touch the ground. Torque lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.

Reassembly

1. All components should be installed in reverse order of removal with special attention to bearing cap orientation and shim placement
2. New pinion shaft lock pin must be installed; do not reuse the old pin
3. All gear oil should include limited slip friction modifier additive to ensure proper clutch pack operation
4. Allow RTV silicone to cure fully before returning vehicle to service

Verification

• Check for gear oil leaks around differential cover and fill plug after installation
• Test drive vehicle in a safe area, making several low-speed turns in both directions to distribute gear oil through clutch packs
• Listen for abnormal noises such as chattering, grinding, or whining from rear differential during test drive
• Verify both rear wheels turn together under power, indicating limited slip function is working properly
• Recheck differential oil level after test drive and top off if necessary
• Inspect for leaks again after test drive; some initial seepage is normal but should not continue

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