1. Remove differential/pumpkin from axle housing/IRS; see instructions on installing gears in 8.8" solid or IRS axles.
2. For 8.8" IRS, remove the differential shaft retaining bolt and differential shaft.
3. Remove the differential bearing caps; Bearing caps must be reinstalled on same side of differential as they were removed.
4. Pinion gear does not need to be removed.
5. Ring gear does not need to be removed from differential.
Rebuilding Clutch Packs
6. Use hammer to tap S-spring from differential.
7. Rotate spider gears (small gears) and remove; make sure concave washers stay with spider gears.
8. Remove side gears and clutch packs.
9. Remove clutch pack shim from between clutch pack and differential.
10. Measure and record thickness of shims.
11. Install friction and steel disks in alternating order; there will be four(4) friction disks and three steel disks on each side gear; the order will be FD/SD/FD/SD/FD/SD/FD.
12. Place the original shims on each side gear/clutch-pack assembly and install assembles into the differential.
13. Place spider gears on side gears such that the shaft holes are aligned.
14. Attempt to rotate the spider gears into place; adjust the thickness of the shims until the side gears cannot be rotated into place; this will necessitate trial and error until both shims are just large enough to where the spider gears will not rotate into place.
15. Reduce each shim size by .005" and rotate spider gears into place.
16. Use a hammer or a press to install S-spring; when using a hammer to reinstall the S-spring, vise-grips can be used to compress the spring to make install a little easier.
17. Make sure the S-spring is in the proper position of the C-clip will not fit into place.
18. On IRS differentials, reinstall the differential shaft and retaining bolt.
Re-Installing Differential/Re-Assembling Axle/IRS
See instructions on installing gears in 8.8" solid or IRS axles.
These
Instructions
