Assembly

1. Lubricate differential gear teeth, thrust faces, splines and the clutch discs and plates.

Fig. 13 Exploded view of Trac-Lok differential:

2. Assemble clutch packs, placing discs and plates in original position. Then, install retainer clips.

Fig. 16 Installing first side gear & clutch pack assembly:

3. Install clutch packs on differential side gears, then install one assembly in case. Ensure clutch packs remain assembled on side gear splines and the retainer clips are fully seated in case pockets.
4. Mount case assembly on axle shaft while clutch packs in place. Ensure that the side gear and axle shaft splines are properly aligned when mounting case on shaft. Also, ensure the clutch packs are properly assembled in case.
5. Install step plate tool in side gear. Apply a small amount of grease to centering hole of step plate.

Fig. 17 Installing second side gear & clutch pack assembly:

6. Install remaining clutch pack and side gear. Ensure clutch packs remain assembled on side gear splines and the retainer clips are fully seated in case pockets.
7. Position gear rotating tool in upper side gear.
8. Hold side gear and gear rotating tool in position and insert forcing screw through top of case and thread into gear rotating tool.
9. Install both differential pinion gears into case, ensuring gear bores are aligned.
10. Tighten forcing screw to compress bevelled springs and provide clearances between teeth of pinion and side gears.
11. Place pinion gears in case and insert rotating tool pawl between side gear teeth. Rotate side gears by pulling on tool handle and install pinion gears. If the side gears will not rotate, adjust bevelled spring load. Loosen or tighten forcing screw to permit side gear rotating.
12. Rotate side gears until shaft bores are aligned with case bores.
13. Lubricate pinion gear thrust washers.
14. Tighten or loosen forcing screw to permit thrust washer installation. Install thrust washers using a small screwdriver to guide washers into position. Ensure that the shaft bores in the thrust washers and gears are properly aligned with case bores.
15. Remove forcing screw, gear rotating tool and step plate.

Fig. 18 Installing pinion mate shaft:

16. Lubricate pinion mate shaft and seat shaft in case using a hammer. Ensure that the snap ring grooves in shaft are exposed to permit snap ring installation.
17. Install pinion mate shaft snap rings.
18. Remove case from axle shaft.
19. Adjust side bearings for zero preload, then install ring gear as outlined for standard differential.