To determine the length of the recess, you'll need to measure from the tip of the half-shaft to the back-side of the retaining clip. (See Fig. 1) If the Tru-Trac diff is like other C-clip diffs, it uses a pin or block through the case for holding the c-clips in place. The Torsen uses a center block.
Referreing to Figs. 2, once the diff is apart, place the side gear on the center block and use the tip-to-retaining clip dimension for determining the length of the recess. The Torsen has a large washer between the side gear and the center block so be sure this washer was in place when determining the length of the recess. As a reference, the recess I machined in each of my Torsen T-2 side gears was 0.090" deep.
The recess for the retaining clip needs to be cut only as deep as the splines. By this, it is meant that the splines are machined off and this is the depth of the recess. (See Fig. 3)
IMPORTANT: Make sure you cut a tapered surface on the face of the splines (essentially making a ramped surface on the face of the splines). If you cut the splines straight, you'll find it nearly impossible to release the half shafts from the side gears. A 45 degree face works great.
The Torsen requires all eight worm gears, two side gears, two thrust washers and two C-clip washers to go in as an assembly. I used large HVAC cable ties to hold the cluster together while inserting it in the case. As a note, re-installing the internal components is a VERY tedious job.
However, the effort is well worth it. Turn-in, mid-corner and corner exit manners are absolutely wonderful with the Torsen T-2.
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