Disassembly and Assembly - Trac-Lok
DISASSEMBLYThe Trac-Lok differential on this axle has a one-piece cross shaft and uses one dished disc, regular 5 disc and 7 plates.
NOTE: Pay attention to the clutch pack arrangement during disassembly. Note the direction of the concave and convex side of the plates and discs.
1. Mark the ring gear half and cover half for installation reference (Fig. 36).
2. Remove case attaching bolts and remove the button cover half (Fig. 37).
3. Remove top clutch pack.
4. Remove top side gear clutch ring.
5. Remove top side gear.
6. Remove pinion mate gears and cross shaft.
7. Remove the same parts listed above from the ring gear flange half of the case. Keep these parts with the flange cover half for installation in their original positions.
ASSEMBLY
The Trac-Lok differential for this axle has a one-piece cross shaft and uses one dished disc, 5 regular disc and 7 plates for each clutch pack.
NOTE: The clutch discs are replaceable as complete sets only. If one clutch disc pack is damaged, both packs must be replaced.
Lubricate each component with gear lube before assembly and installation.
1. Saturate the clutch plates with Mopar Hypoid Gear Lubricant or Additive.
2. Assembly the discs and plates on the side gear (Fig. 38) in the following order.
a. Install dished disc on side gear.
b. Install one disc on side gear.
c. Install one plate on side gear.
d. Install one disc on side gear.
e. Install one plate on side gear.
f. Install three discs on side gear.
g. Install five plates on side gear.
3. Line up the plate ears and install the assembled pack into the flange half (Fig. 39). Verify clutch plate lugs enter the slots in the case and clutch pack bottoms out in the case.
4. Install pinion mate shafts and pinion mate gears (Fig. 40). Verify shafts are correctly installed according to the alignment marks.
5. Lubricate and install the other side gear and clutch pack (Fig. 39).
6. Correctly align and assemble button half to flange half. Install case body screws finger tight.
7. Tighten body screws alternately and evenly. Tighten screws to 122 - 136 Nm (90 - 100 ft. lbs.) (Fig. 41).