Disassembly and Assembly - Trac-Lok
REMOVAL1. Raise and support vehicle.
2. Remove fill hole plug from the differential housing cover.
3. Remove differential housing cover and drain 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 the axle shafts.
NOTE: Side play resulting from bearing races being loose on case hubs requires replacement of the differential case.
6. Mark the differential housing and bearing caps for installation reference (Fig. 28).
7. Remove bearing threaded adjuster locks from each bearing cap.
8. Loosen bearing cap bolts, them loosen the threaded adjusters with Wrench C-4164.
9. Hold the differential case while removing bearing caps and adjusters.
10. Remove the differential case.
NOTE: Tag bearing cups and threaded adjusters location, for installation reference.
DISASSEMBLY
1. Clamp side gear Holding Fixture 6963 in a vise and position the differential case on the Holding Fixture (Fig. 34).
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. 35).
5. Install and lubricate Step Plate C-4487-1 (Fig. 36).
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. 37) 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. 38).
9. With a feeler gauge remove thrust washers from behind the pinion gears (Fig. 39).
10. Insert Turning Bar C-4487-4 into the pinion mate shaft hole in the case (Fig. 40).
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. 41).
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. 42).
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. 43). 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. 44).
7. Install the upper side gear and clutch disc pack (Fig. 44).
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
1. Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups and threaded adjusters. A dab of grease can be used to keep the adjusters in position. Carefully position the assembled differential case in the housing.
2. Install differential bearing caps in their original locations (Fig. 31).
3. Install bearing cap bolts and tighten the upper bolts to 14 Nm (10 ft. lbs.). Tighten the lower bolts finger-tight until the bolt head is seated.
4. Perform the differential bearing preload and adjustment procedure.
5. Tighten bearing cap bolts in a crisscross pattern to 95 Nm (70 ft. lbs.).
6. Install adjuster locks on the bearing caps.
7. Install axle shafts.
8. Apply a bead of red Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 32).
CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.
9. Install cover and tighten bolts in a crisscross pattern to 41 Nm (30 ft. lbs.).
10. Fill differential with gear lubricant to bottom of the fill plug hole.
11. Install the fill hole plug.
12. Install wheel and tire assemblies.
13. Remove support and lower vehicle.
14. Trac-LOK differential equipped vehicles should be road tested by making 10 to 12 slow figure-eight turns. This maneuver will pump the lubricant through the clutch discs to eliminate a possible chatter noise complaint.