Differential Case and Ring Gear Traction-LOK(R)

Differential Case and Ring Gear - Traction-Lok (R)

Material:

Disassembly

1. Remove the differential case.

NOTE: When refilling the axle with lubricant, first add 0.163 L (5.5 ounces) of friction modifier.

2. Match-mark the differential case.
1 Match-mark the differential case flange (ring gear) and button (cover) halves.
2 Match-mark the differential pinion shafts and corresponding ramps.





3. NOTE: An axle shaft held in a vise, with the shaft splines extending not more than 3 inches above the vise jaws, makes an excellent holding fixture for the differential case.

Loosen, but do not remove, the bolts.





4. Place the differential assembly on a bench.
5. Remove the bolts and the button half of the differential case.





6. Remove the differential side gear, side gear ring, rear axle disc and plate kit, differential pinion gears and the differential pinion shafts. Keep these parts in order for correct installation by placing them aside with the button half of the differential case.





7. Remove the side gear ring and the rear axle disc and plate kit from the flange half of the differential case. Keep these parts in order by placing them on the pinion flange as shown.





8. Inspect these components:
^ The clutch plates and clutch discs for cracks, excessive wear and distortion. Always install an entirely new rear axle disc and plate kit on both sides if discarding one or more of the clutch plates or clutch discs.
^ The differential pinion shafts and the ramp surfaces on the differential case for excessive wear or pitting.
^ The differential side gear and differential pinion gear teeth.
^ The differential side gear races that bear on the differential side gear rings.

Assembly
1. Soak the clutch packs for 20 minutes in friction modifier before assembly.
2. Place the side gear ring on the pinion flange. Coat the rear axle disc and plate kit with lubricant and place it on the side gear ring.
^ Use rear axle lubricant or friction modifier.





3. CAUTION: After assembly, make sure that the side gear splines engage the clutch pack splines and the differential side gear is fully seated.

Install the side gear ring, the rear axle disc and plate kit and the side gear in the flange half of the differential case.





4. NOTE: For vehicles operating at close to their GVW rating, typically emergency vehicles and vehicles equipped with a fifth wheel, there may be circumstances of continuing chatter/bumping in turns despite the installation of new parts and lubricant. In cases such as this, it is permissible to reassemble the rear axle disc and plate kit with the clutch disc adjacent to the differential side gear ring, resulting in 2 clutch plates together. This results in 3 friction surfaces instead of the normal 5, lowering the torque to rotate the wheel by 40 percent.

Align the clutch pressure plate lugs, and install the side gear ring, the clutch pack and differential side gear in the button half of the differential case.





5. CAUTION: Align the match marks made during disassembly.

Place the differential pinion shaft and differential pinion gears in the button half of the differential case.





6. CAUTION: Align the match marks made during disassembly.

Install the other differential pinion shaft and differential pinion gears in the flange half of the differential case.





7. CAUTION: Align the match marks made during disassembly.

Assemble the differential case.
1 Place the button half of the differential case onto the flange half of the differential case assembly.

2. CAUTION: The bolts must be clean and dry.

Install the bolts. Turn each one in a few threads.
3 Tighten the bolts evenly and alternately.
^ Tighten to 129 Nm (95 ft. lbs.).





8. If assembled correctly, each differential pinion shaft will fit tight on its ramp. Clearance between the differential pinion shaft and the ramp must not be more than 0.254 mm (0.010 inch) and it must be equal at all 4 ends of the differential pinion shafts.
9. Install the differential case.