Parts you are going to need:
LSD clutch packs - 33141210626 Quantity of 2 needed
Diff cover gasket - 33111211708
Drain and Fill plug gaskets - 33111206166 I bought 20 just because these are one time use items, you can never have enough, and THEY ARE CHEAP.
Doing this will bring your differential back to its full 25% lock up capability. It is intimidating but not hard at all if you take your time and are methodical about your work.
Take pictures, draw diagrams, lay everything out in order. Anything so you can reference the order of parts inside the LSD unit.
This is a 3.23 with the diff cover off and fluid drained.
Take a flathead screwdriver or small prybar and gently turn and pry out the output flanges.
Be careful as the piece you are prying on the flange is very weak and will bend if you are rough with it.
Output flanges pulled out.
Next, take out the oil seals on both sides. Take out the 6 bolts and remember the orientation for when you reinstall them. These pull out the same way the output flanges do except more force is needed and you may need to use 2 pry tools on both sides of the seal.
You can see here as you take one seal out the LSD unit will then become unsupported. Once you take the other side out there will be no support for the LSD so be ready so it will not fall out of the housing.
oil seals safe on their output shafts
and finally here is the LSD unit.
Next is to take off the cover. The 8 allen bolts are 6mm and will need to be taken out. Take care though as these are known for stripping the heads. An impact type tool really facilitates the process but you do not want something too strong as you run the risk of stripping it. I used a 16volt 3/8 impact gun that worked great.
Make sure the allen socket is in deep and square to prevent strippage.
cover off
here's what you'll find when you take the cover off. This is the part where you pay the most attention and reference everything in anyway you can!
notice the orientation of the spacer, which needs to be correct in order for the cover to go back on.
slowly start taking the pieces out in order onto a prepared surface where you can keep track of everything.
#4 is the first clutch pack.
old on top, new on bottom. You can see the wear.
old
new
reach in and under to pull this piece out.
Reach in and under. You may pull up the clutch pack and a spacer with it. Make sure to reference the order if you do pull these out with the larger piece.
This is as deep as you need to go.
Put everything back in the correct order with the new clutch packs.
Make sure when you put the LSD cover back on the unit that the top spacer key is oriented correctly. If not the cover will not fit on.
Whether you use new high grade hex hardware or the old allen bolts for the LSD cover make sure you use red loctite.
When reinstalling the unit I found it easier if you place the entire housing on the input shaft. That way the LSD unit can rest inside the housing while you reinstall the oil seals.
PHEW. There will probably be lots of editing this post but here ya go!
Big thanks to Cal as he was the one who first did this and answered a bunch of questions for me before I did it.
LSD clutch packs - 33141210626 Quantity of 2 needed
Diff cover gasket - 33111211708
Drain and Fill plug gaskets - 33111206166 I bought 20 just because these are one time use items, you can never have enough, and THEY ARE CHEAP.
Doing this will bring your differential back to its full 25% lock up capability. It is intimidating but not hard at all if you take your time and are methodical about your work.
Take pictures, draw diagrams, lay everything out in order. Anything so you can reference the order of parts inside the LSD unit.
This is a 3.23 with the diff cover off and fluid drained.
Take a flathead screwdriver or small prybar and gently turn and pry out the output flanges.
Be careful as the piece you are prying on the flange is very weak and will bend if you are rough with it.
Output flanges pulled out.
Next, take out the oil seals on both sides. Take out the 6 bolts and remember the orientation for when you reinstall them. These pull out the same way the output flanges do except more force is needed and you may need to use 2 pry tools on both sides of the seal.
You can see here as you take one seal out the LSD unit will then become unsupported. Once you take the other side out there will be no support for the LSD so be ready so it will not fall out of the housing.
oil seals safe on their output shafts
and finally here is the LSD unit.
Next is to take off the cover. The 8 allen bolts are 6mm and will need to be taken out. Take care though as these are known for stripping the heads. An impact type tool really facilitates the process but you do not want something too strong as you run the risk of stripping it. I used a 16volt 3/8 impact gun that worked great.
Make sure the allen socket is in deep and square to prevent strippage.
cover off
here's what you'll find when you take the cover off. This is the part where you pay the most attention and reference everything in anyway you can!
notice the orientation of the spacer, which needs to be correct in order for the cover to go back on.
slowly start taking the pieces out in order onto a prepared surface where you can keep track of everything.
#4 is the first clutch pack.
old on top, new on bottom. You can see the wear.
old
new
reach in and under to pull this piece out.
Reach in and under. You may pull up the clutch pack and a spacer with it. Make sure to reference the order if you do pull these out with the larger piece.
This is as deep as you need to go.
Put everything back in the correct order with the new clutch packs.
Make sure when you put the LSD cover back on the unit that the top spacer key is oriented correctly. If not the cover will not fit on.
Whether you use new high grade hex hardware or the old allen bolts for the LSD cover make sure you use red loctite.
When reinstalling the unit I found it easier if you place the entire housing on the input shaft. That way the LSD unit can rest inside the housing while you reinstall the oil seals.
PHEW. There will probably be lots of editing this post but here ya go!
Big thanks to Cal as he was the one who first did this and answered a bunch of questions for me before I did it.
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