Limited Slip Differential Assemble

Limited Slip Differential Assemble

^ Tools Required
- J 45709 Limited Slip Differential Overhaul Kit - Dana 248

Important:
^ The clutch discs are replaceable as complete sets only. If one clutch disc pack requires replacement, both packs must be replaced.
^ New clutch discs and clutch plates need to be soaked in the lubricant that is provided in the kit for 20 minutes before the clutch packs can be assembled.

1. Soak the clutch discs and the clutch plates in the lubricant provided with the kit for 20 minutes.





2. Assemble the components of each clutch pack onto the left and right side differential side gear (1) in the following order:
1. The limited slip clutch disc spacer (2)
2. The 1st non-eared clutch disc (3)
3. The 1st eared clutch plate (4)
4. The 2nd non-eared clutch disc (5)
5. The 2nd eared clutch plate (6)
6. The 3rd non-eared clutch disc (7)
7. The 3rd eared clutch plate (8)
8. The 4th non-eared clutch disc (9)
9. The 4th eared clutch plate (10)

3. Install the two differential clutch retainers to the each of the clutch packs. Ensure that the differential clutch retainers are fully seated onto the ears of the clutch plates.
4. Install the left side differential side gear and clutch pack into the flange end of the differential case.
5. Install the right side differential side gear and clutch pack into the bell end of the differential case.





6. While holding the bell end differential side gear in position, install the J 45709-2 (1) and the J 45709-3 (2) into the differential case.
7. Tighten the J 45709-2 (1) until there is enough clearance to install the pinion gears.





8. Install the J 45709-1 (2).While holding the pinion gears against the side gears, rotate the differential using the J 45709-1 until the pinion gears align with the pinion shaft bore.





Notice: Refer to Fastener Notice in Service Precautions.

9. Tighten the J 45709-2 (1).
^ Tighten the J 45709-2 to 40 Nm (30 ft. lbs.).

10. Lubricate the differential pinion gear thrust washers with the lubricant provided in the kit.





11. Install the differential pinion gear thrust washers. If the thrust washers cannot be installed, continue to tighten the J 45709-2 as necessary until the thrust washers can be installed.
12. Remove the J 45709-2.
13. Remove the J 45709-3.





14. Install the pinion shaft.





15. Using a brass drift, install a new roll pin.
Drive the roll pin into the differential case until it is approximately 44.5 mm (1.75 inch) below the surface of the differential case.
16. Install the differential side bearings, if necessary.
17. Install the ring gear, if necessary.