Disassembly and Assembly - Trac-Lok
REMOVAL1. Raise and support the vehicle.
2. Remove fill hole plug from the differential housing cover.
3. Remove differential housing cover and drain lubricant from the housing.
4. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. Do not use water, steam, kerosene or gasoline for cleaning.
5. Remove axle shafts.
6. Note the orientation of the installation reference letters stamped on the bearing caps and housing machined sealing surface (Fig. 28).
7. Remove the differential bearing caps.
8. Position Spreader W-129-B with the tool dowel pins seated in the locating holes (Fig. 29).
9. Install the hold down clamps and tighten the tool turnbuckle finger-tight.
10. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach dial indicator to housing pilot stud. Load the indicator plunger against the opposite side of the housing (Fig. 29) and zero the indicator.
11. Spread the housing enough to remove the case from the housing. Measure the distance with the dial indicator (Fig. 29).
CAUTION: Never spread the housing over 0.50 mm (0.020 inch). If housing is over-spread, it could be distorted or damaged.
12. Remove the dial indicator.
13. Pry the differential case loose from the housing. To prevent damage, pivot on housing with the end of the pry bar against spreader (Fig. 30).
14. Remove the case from housing. Tag bearing cups to indicate their location.
DISASSEMBLY
1. Clamp side gear Holding Fixture 6963 in a vise and position the differential case on the Holding Fixture (Fig. 38).
2. Remove ring gear if the ring gear is to be replaced. The Trac-LOK differential can be serviced with the ring gear installed.
3. Remove pinion gear mate shaft roll-pin with a punch and hammer.
4. Remove pinion gear mate shaft (Fig. 39).
5. Install and lubricate Step Plate C-4487-1 (Fig. 40).
6. Assemble Threaded Adapter C-4487-3 into top side gear. Thread Forcing Screw C-4487-2 into adapter until it becomes centered in adapter plate.
7. Position a small screw driver in slot of Threaded Adapter Disc C-4487-3 (Fig. 41) to prevent adapter from turning.
8. Install Forcing Screw C-4487-2 and tighten screw to 122 Nm (90 ft. lbs.) maximum to compress Belleville springs in clutch packs (Fig. 42).
9. With a feeler gauge remove thrust washers from behind the pinion gears (Fig. 43).
10. Insert Turning Bar C-4487-4 into the pinion mate shaft hole in the case (Fig. 44).
11. Loosen the Forcing Screw in small increments until the clutch pack tension is relieved and the differential case can be turned using Turning Bar.
12. Rotate differential case until the pinion gears can be removed.
13. Remove pinion gears from differential case.
14. Remove Forcing Screw, Step Plate and Threaded Adapter.
15. Remove top side gear, clutch pack retainer and clutch pack. Keep plates in correct order during removal (Fig. 45).
16. Remove differential case from the Holding Fixture. Remove side gear, clutch pack retainer and clutch pack. Keep plates in correct order during removal.
ASSEMBLY
NOTE: New Plates and discs with fiber coating (no grooves or lines) must be presoaked in Friction Modifier before assembly. Soak plates and discs for a minimum of 20 minutes.
1. Lubricate components with gear lubricant.
2. Assemble clutch discs into packs and secure disc packs with retaining clips (Fig. 46).
NOTE: Dished plate is position with the convex side against the side gear.
3. Position assembled clutch disc packs on the side gear hubs.
4. Install clutch pack and side gear in the ring gear side of the differential case (Fig. 47). Be sure clutch pack retaining clips remain in position and are seated in the case pockets.
5. Position the differential case on the Holding Fixture 6963.
6. Install lubricated Step Plate C-4487-1 in lower side gear (Fig. 48).
7. Install the upper side gear and clutch disc pack (Fig. 48).
8. Hold assembly in position. Insert Threaded Adapter C-4487-3 into top side gear.
9. Install Forcing Screw C-4487-2 and tighten screw to slightly compress clutch disc.
10. Place pinion gears in position in side gears and verify that the pinion mate shaft hole is aligned.
11. Rotate case with Turning Bar C-4487-4 until the pinion mate shaft holes in pinion gears align with holes in case. It may be necessary to slightly tighten the forcing screw in order to install the pinion gears.
12. Tighten forcing screw to 122 Nm (90 ft. lbs.) maximum to compress the Belleville springs.
13. Lubricate and install thrust washers behind pinion gears and align washers with a small screw driver. Insert mate shaft into each pinion gear to verify alignment.
14. Remove Forcing Screw, Step Plate and Threaded Adapter.
15. Install pinion gear mate shaft and align holes in shaft and case.
16. Install and seat pinion mate shaft roll-pin in case with a hammer and punch. Peen the edge of the roll-pin in the case slightly in two places 180 degrees apart.
17. Lubricate all differential components with hypoid gear lubricant.
INSTALLATION
NOTE: If replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Refer to Adjustments (Differential Bearing Preload and Gear Backlash) procedures to determine proper shim selection.
1. Position Spreader W-129-B with the tool dowel pins seated in the locating holes. Install the hold down clamps and tighten the tool turnbuckle finger tight.
2. Install a Pilot Stud C-3288-B at the left side of the differential housing and attach dial indicator to the pilot stud. Load the indicator plunger against the opposite side of the housing and zero the dial indicator.
3. Spread the housing enough to install the case in the housing. Measure the distance with the dial indicator.
CAUTION: Never spread the housing over 0.50 mm (0.020 inch). If housing is over-spread, it could be distorted or damaged.
4. Remove the dial indicator.
5. Install differential into the housing. Tap the differential case with a rawhide/rubber hammer to ensure the bearings are seated in housing (Fig. 34).
6. Remove the spreader.
7. Install bearing caps in their original locations (Fig. 35) and tighten bearing cap bolts in a crisscross pattern to 108 Nm (80 ft. lbs.).
8. Install axle shafts.
9. Install the hub bearings.
10. Apply a bead of red Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 36).
CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.
11. Install the cover and tighten bolts in a crisscross pattern to 47 Nm (35 ft. lbs.).
12. Fill the differential with Mopar Hypoid Gear Lubricant or equivalent to bottom of the fill plug hole.
13. Install fill hole plug and tighten to 34 Nm (25 ft. lbs.).
14. Remove support and lower vehicle.