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POSITRACTION Differential: Overhaul: Reassembly

  1. Lubricate clutch discs and plates with positraction lubricant. Alternately place clutch plates and discs on one side gear, beginning and ending with a clutch plate. Position side gear, clutch pack and original shim in case.
  2. Install both pinion gears and thrust washers into case and install pinion shaft. Place case onto splined end of axle shaft supported in vise until splines in side gear engages splines on axle shaft. Insert screwdriver between pinion shaft and face of side gear and force in until clutch pack is compressed.
  3. With clutch pack fully compressed, measure backlash between side gear and pinion gears. Adjust shims as necessary to obtain backlash of 0.005 - 0.008". Remove pinion shaft, pinion gears and thrust washers, side gear, clutch pack and shims from case. Repeat backlash procedure for opposite side gear.
  4. With proper shim thickness determined, install shims, clutch packs, and side gears into case. Position differential case on axle shaft supported in vise. Place both pinion gears and thrust washers into position, 180° apart, and carefully roll into position by turning case on shaft.
    NOTE: Large "C" clamp may be used to apply slight compression against pinion gears to aid in "rolling in" procedure.
  5. With internal gears in correct position, gently tap reload spring into place. Install pinion shaft and lock screw. Press differential side bearings onto journals on case and install ring gear.
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