Limited Slip Differential Assemble

Tools Required 

J 45709  Limited Slip Differential Overhaul Kit - Dana 248. See Special Tools and Equipment .

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)
Fig 1: Clutch Pack Components
Courtesy of GENERAL MOTORS CORP.
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.
Fig 2: Installing J 45709-2 & J 45709-3 Into Differential Case
Courtesy of GENERAL MOTORS CORP.
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.

Fig 3: J 45709-2, J 45709-1 & J 45709-3
Courtesy of GENERAL MOTORS CORP.
NOTE: Refer to Fastener Notice in Cautions and Notices.
9. Tighten the J 45709-2 (1).

   Tighten:  Tighten the J 45709-2 to 40 N.m (30 lb ft).

Fig 4: Tightening J 45709-2
Courtesy of GENERAL MOTORS CORP.
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.

Fig 5: Installing Differential Pinion Gear Thrust Washers
Courtesy of GENERAL MOTORS CORP.
12. Remove the J 45709-2.
13. Remove the J 45709-3.
14. Install the pinion shaft.
Fig 6: Installing Pinion Shaft
Courtesy of GENERAL MOTORS CORP.
15. Using a brass drift, install a new roll pin.

    Specification:  Drive the roll pin into the differential case until it is approximately 44.5 mm (1.75 in) below the surface of the differential case.

Fig 7: Installing Roll Pin
Courtesy of GENERAL MOTORS CORP.
16. Install the differential side bearings, if necessary. Refer to Differential Side Bearings Replacement (All Except 9.75 Inch Axle) or Differential Side Bearings Replacement (9.75 Inch Axle) in Rear Drive Axle.
17. Install the ring gear, if necessary. Refer to Drive Pinion and Ring Gear Replacement (8.6 Inch, 9.5 Inch, 11.5 Inch Axles) or Drive Pinion and Ring Gear Replacement (9.75 Inch Axle) or Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) in Rear Drive Axle.