JREPosiModificationInstructionsV2Removethe8Torx.docVIP

JRE Posi Modification Instructions V2 Remove the 8 Torx Bolts holding the two posi halves together. You will need an E18 Socket. Note: Do not worry about orientation of the case because it can only be installed one way. This is because the two halves of the case utilize a roll pin that engages in both case halves. Were going to remove both stacks of clutches and put them aside temporarily. The two side gears and two spider gears have bumps cast in and will have to be modified on a belt sander to make the gear face surface flat. (This modification will make sure that there will be no wear on the new preload spring that will be added later in these instructions) Your gears will now look this, notice how they are flat and have no casting marks in them. Now we go back to the Clutches. Out of the original clutches, you will be using one clutch steel and one double sided friction from each clutch pack. All else will be discarded. Take your new clutch packs and stack them as follows onto the side gears. 1st Single Sided Friction with friction surface facing up then alternate steel, double sided friction, steel, original double sided friction, and original steel. Your new clutch pack will be approximately .530 inch thick. Repeat for other side gear. (NOTE: Soak friction surfaces with posi additive ) Lower one pack and gear assembly into housing as shown. Next slide pre-load spring over cross pin and reinstall spider gears being certain to line up hole in cross pin with the hole in the side case. Then stack remaining side gear and clutch pack assembly as shown.  Lower last case halve over the clutches lining up ears on steels with recess in case halve being sure to line up roll pin into the cross pin. Carefully flip entire assembly over, reinstall 8 case halve bolts with loctite red. Snug assembly together in a criss cross pattern. Finally torquing bolts. They should be torqued in three stages. 35 Ft lbs first, followed by 45 Ft lbs and finishing with 55