Trac-Lok Differential Carrier - Assembly

ASSEMBLY

Special Tools:

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 (2), plates (6) and belleville spring (1) into packs and secure disc packs with retainers (5).

NOTE: Belleville spring (1) is position with the convex side against the differential case.

3. Position assembled clutch disc packs on the side gear (4) hubs.




4. Install lower clutch pack and side gear (1) in the differential case (2), with retaining clips seated in the case pocket.





5. Install upper clutch disc pack (1) retaining clips (2) and side gear (3) with seated in the case pocket.





6. Lubricated and install discs into side gears from Trac-lok(R) Tool C-4487. Install forcing screw from Trac-lok(R) Tool C-4487 and thread screw to compress belleville springs in clutch packs.
7. Install pinion gears (2) in side gears opposite each other.





8. Rotate differential case (2) with turning bar (1) from Trac-lok(R) Tool C-4487 until pinion gears align with mate shaft holes in the case. NOTE: Loosen forcing screw in small increments to relieve clutch pack tension if differential case can not be rotated.






9. Install pinion gear thrust washers (1) between the gear and case (2). Align washers with mate shaft hole in the case.





10. Remove forcing screw upper disc from side gear.
11. Remove lower disc (1) from side gear (2).





12. Install pinion mate shaft (3) in case (1).





13. Install pinion mate shaft (1) roll pin (2).
14. Install ring gear.
15. Lubricate all differential components with gear lubricant.