Disassembly and Assembly - Trac-Lok
REMOVAL1. Remove filler plug from the differential cover.
2. Remove differential cover and drain the lubricant.
3. Clean housing cavity with flushing oil, light engine oil or a lint free cloth.
NOTE: Do not use steam, kerosene or gasoline to clean the housing.
4. Remove axle shafts.
5. Remove RWAL/ABS sensor from housing.
NOTE: Side play resulting from bearing races being loose on case hubs requires replacement of the differential case.
6. Mark differential housing and bearing caps for installation reference (Fig. 29).
7. Remove bearing threaded adjuster lock from each bearing cap.
8. Loosen differential bearing cap bolts.
9. Loosen differential bearing adjusters through the axle tubes with Wrench C-4164.
10. Hold differential case while removing bearing caps and adjusters.
11. Remove differential case.
NOTE: Tag the differential bearing cups and threaded adjusters to indicate their location.
DISASSEMBLY
1. Clamp side gear Holding Fixture 6965 in a vise and position the differential case on the Holding Fixture (Fig. 35).
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 the pinion gear mate shaft lock screw (Fig. 36).
4. Remove pinion gear mate shaft with a drift and hammer (Fig. 37).
5. Install and lubricate Step Plate C-6960-3 (Fig. 38).
6. Assemble Threaded Adapter C-6960-1 into top side gear. Thread Forcing Screw C-6960-4 into adapter until it becomes centered in adapter plate.
7. Position a small screw driver in slot of Threaded Adapter Disc C-6960-1 (Fig. 39) to prevent adapter from turning.
8. Install Forcing Screw C-6960-4 and tighten screw to 122 Nm (90 ft. lbs.) maximum to compress Belleville springs in clutch packs (Fig. 40).
9. With a feeler gauge remove thrust washers from behind the pinion gears (Fig. 41).
10. Insert Turning Bar C-6960-2 into the pinion mate shaft hole in the case (Fig. 42).
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. 43).
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 each component with gear lubricant before assembly.
2. Assemble the clutch discs into packs and secure disc packs with retaining clips (Fig. 44).
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. 45). 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 6965.
6. Install lubricated Step Plate C-6960-3 in lower side gear (Fig. 46).
7. Install the upper side gear and clutch disc pack (Fig. 46).
8. Hold assembly in position. Insert Threaded Adapter C-6960-1 into top side gear.
9. Install Forcing Screw C-6960-4 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-6960-2 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 pinion mate shaft lock screw finger tight to hold shaft during differential installation.
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.
2. Install differential assembly into the housing.
3. Install differential bearing caps in their original locations (Fig. 32).
4. 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.
5. Perform the differential bearing preload and adjustment procedure.
NOTE: Be sure that all bearing cap bolts are tightened to their final torque of 136 Nm (100 ft. lbs.) before proceeding.
6. Install axle shafts.
7. Apply a 1/4 inch bead of red Mopar Silicone Rubber Sealant or equivalent to the housing cover (Fig. 33).
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.
8. Install the cover and any identification tag and tighten cover bolts to 41 Nm (30 ft. lbs.).
9. Fill differential with lubricant to bottom of the fill plug hole. Refer to the Lubricant Specifications for the correct quantity and type.
NOTE: 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.