Differential Trac-Lok

DIFFERENTIAL TRAC-LOK

REMOVAL





1. Remove drain plug (2) from differential cover (1) and drain lubricant.
2. Clean housing cavity with a flushing oil, light engine oil or lint free cloth.





3. Remove pinion mate shaft (1) lock screw (2).





4. Remove pinion mate shaft (2).





5. Push axle shafts (1) inward and remove axle shafts Clocks (2).
6. Remove axle shafts.





7. Note bearing cap and housing sealing surface location marks (1).
8. Remove differential bearing caps.





9. Position Spreader W129B (4) with tool dowel pins (2) seated in the locating holes. Install hold-down clamps (3) and tighten turnbuckle (5) finger-tight.





10. Install Pilot Stud C3288B (5) on left side of the housing and attach dial indicator (2) to the pilot stud. Load indicator plunger against the opposite side of the housing and zero indicator.





11. Spread (2) housing while measuring the distance with the dial indicator (1).

CAUTION: Never spread the housing over 0.50 mm (0.020 inch). If housing is overspread, it could be distorted or damaged.

12. Remove dial indicator.
13. Hold differential case in position and remove differential bearing caps.
14. Pry differential case loose from housing.





15. Remove case (2) from housing (1) and tag bearing cups (3) and shims location.
16. Remove spreader.

DISASSEMBLY





1. Clamp Holding Fixture 9346 (1) in vise (2) and set differential case (3) on fixture.
2. Remove pinion gear mate shaft screw.
3. Remove pinion gear mate shaft.





4. Lubricate and install disc (3), that is not threaded from Trac-lok Tool Kit 6960 into the lower side gear (1).





5. Install threaded disc (6) from Trac-lok Tool Kit 6960 into top side gear. Thread forcing screw (5) from Trac-lok Tool Kit 6960 through top disc until it comes in contact with lower disc (4).
6. Position a small screw driver (3) in slot of top disc (2) to prevent disc from turning.





7. Tighten forcing screw (2) with torque wrench (1) to 122 Nm (90 ft. lbs.) maximum to compress Belleville springs in clutch packs.





8. With a feeler gauge (2) remove thrust washers (1) from behind the pinion gears.





9. Insert turning bar (2) from tool kit into pinion mate shaft hole in the case.
10. Loosen forcing screw in small increments until the clutch pack tension is relieved and differential case can be turned using turning bar.
11. Rotate differential case until the pinion gears (1) can be removed.
12. Remove pinion gears from differential case.
13. Remove forcing screw and discs.





14. Remove top side gear (3) with clutch pack (3) and retainer (2).

NOTE: Keep plates in correct order during removal.

15. Remove differential case from fixture. Remove lower side gear, clutch pack retainer and clutch pack.

ASSEMBLY





Clean all components in cleaning solvent and dry components with compressed air. Inspect clutch pack plates (1) for wear, scoring or damage. Replace both clutch packs if any one component in either pack is damaged. Inspect side gears and pinions. Replace any gear that is worn, cracked, chipped or damaged. Inspect differential case and pinion shaft. Replace if worn or damaged.

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 clutch discs (1) into packs and secure disc packs with retaining clips (4).
3. Position differential case on the Holding Fixture 9346.
4. Position assembled clutch disc packs on the side gear hubs.





5. Install lower clutch pack (2) with side gear (2) in the differential case (1) and verify clutch pack retaining clips are in position.
6. Install lubricated disc from Trac-lok Tool Kit 6960 into lower side gear.





7. Install upper clutch disc pack (1) with side gear (1) and verify clutch pack retaining clips are in position.
8. Hold assembly in position and install threaded disc from tool kit into top side gear.
9. Install forcing screw from Trac-lok Tool Kit 6960 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 until pinion mate shaft holes in pinion gears align with holes in case.

NOTE: 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, Discs and Threaded Adapter.
15. Install pinion gear mate shaft and align holes in shaft and case.
16. Install pinion mate shaft screw.

INSTALLATION

NOTE: If differential bearings or differential case are replaced, differential side bearing shim requirements may change.





1. Position Spreader W129B with tool dowel pins seated in the locating holes. Install hold down clamps and tighten the tool turnbuckle finger-tight.
2. Install Pilot Stud C3288B on 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 dial indicator.
3. Spread housing while measuring the distance with the dial indicator.

CAUTION: Never spread the housing over 0.50 mm (0.020 inch). Failure to follow these instructions will damage the case.

4. Remove dial indicator.
5. Install differential into the housing. Tap differential case with a soft hammer (1) to ensure bearings are seated.
6. Remove spreader.





7. Install bearing caps in their original locations (1) (2) and tighten bearing cap bolts in a crisscross pattern to 108 Nm (80 ft. lbs.).
8. Install axle shafts.





9. Install axle shaft (1) Clocks (2).





10. Install pinion mate shaft (1) and install mate shaft lock screw (2) and tighten to 27 Nm (20 ft. lbs.).





11. Apply a bead of orange Mopar Axle RTV seal ant (2) or equivalent to the housing cover (1).

CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak.

12. Install cover and tighten bolts in a crisscross pattern to 48 Nm (35 ft. lbs.).
13. Fill differential lubricant to bottom of the fill plug hole.
14. Install fill hole plug and tighten to 27 Nm (20 ft. lbs.).