Disassembly

Fig. 12 Measuring axle shaft:

1. Mount one axle shaft in a vise with the splined end facing upward. Do not allow end of shaft to extend more than 2-3/4 inch above top of vise. This prevents the shaft from fully entering the side gear.
2. Mount differential case on axle shaft with ring gear bolt heads facing upward.

Fig. 13 Exploded view of Trac-Lok differential:

3. Remove ring gear bolts.
4. Loosen ring gear with a mallet, remove case from axle shaft, then the ring gear.
5. Remount differential case on axle shaft, then remove pinion gear mate shaft retaining roll pin.
6. Remove pinion mate shaft with a suitable drift and hammer. The gear rotating tool J-23781 or equivalent is required to perform the following steps. The tool consists of three parts: gear rotating tool, forcing screw and step plate.
7. Install step plate in lower differential side gear.
8. Assemble threaded adapter into top side gear. Thread forcing screw into adapter until it becomes centered in adapter plate.
9. Position a screwdriver in slot of threaded adapter. This will prevent adapter from turning.
10. Tighten forcing screw tool enough to relieve clutch pack tension, then remove both pinion thrust washers.
11. Loosen forcing screw tool until clutch pack tension is relieved.
12. Insert turning bar in case. Rotate case with tool until pinion gears can be removed. Remove tools from case.

Fig. 15 Separating plates & discs:

13. Remove top side gear and clutch pack. Keep plates in correct order during removal.
14. Remove case from holding fixture. Remove remaining clutch pack.
15. Remove clutch pack retaining clips. Mark each clutch pack for installation reference.