Has anybody replaced/rebuilt their limited slip clutch pack on the rear end of a truck? My excursion seems to be a one wheel wonder, not the limited slip its listed as having!

 

If it's like the 8.8" diff in my Mustang, it's a pretty simple replacement. Ford sells a complete kit that includes new clutch and steel plates for both sides, a cross pin retaining bolt, C-clips, and a small bottle of friction modifier. You remove the cross pin retainer bolt (a little heat on it can soften the thread lock), pull the cross pin, S-spring, which will allow the axle shafts to be pushed in to remove the C-clips, remove the spider gears, and you can pull the clutch pack (with the side gears).

I did a trick that the Mustang racers do to try to make the locking more effective. The stock clutch pack was like:

SCPPCPPCG - where C is a clutch plate and P is a steel driven plate, S is a shim, and G is the side gear that the pack goes into.

The modification I did was:

SCPCPCPCG

This replaced one of the steel plates with the old clutch plate that was pushed against the gear housing before, as only half of that surface was in contact, and worn. I would scuff the worn surface a little and put it against the shim. So this adds two more friction surfaces to engage the steel driven plates, which will engage the locking action with less side force. It will make the pre-load from the S-spring more effective as well. Other than that, assembly is the reverse of dis-assembly.