[dwydendorf]

I spent more than half my life at the place where the original posi's were built and developed. Allmost all the service units used to be built by hand, they used channel lock pliers to install the preload plates and pounded them in with a hammer. Put as much shim as you can and still assemble the unit-to still be able to put in the pinion gears and washers. They used Texaco Marvak grease to hold the clips on the clutch packs and used gear lube to soak the individual clutches before assembly. It helps if you have a t wrench made from about a 6 inch piece of axle splined to turn the top gear. All the clutch packs were broken in on the factory units, so you may have to take the unit out and reshim if you use new clutch discs that aren't broken in. Make sure you don't use the slotted clutch discs, those were designed to prevent from breaking axles in the oem units unless you can't get anything else. The original units built before the 1980's had cut gears (with the gear teeth cut after the blank was machined)in them but in the 1980's they went to a forged tooth gear (gears were machined by locating on the gear teeth) that was far better than the earlier cut gears. The earlier gears can't be used with the later gears. Hope this provides some more info than what you had.