Differential Case and Ring Gear - Traction-Lok(R)
Differential Case and Ring Gear - Traction-Lok(R)
Disassembly
1. Remove the differential assembly from the differential housing. For additional information, refer to Differential Case Differential Case.
2. Remove and discard the 10 differential ring gear bolts.
3. NOTICE: Do not damage the bolt hole threads.
Insert a punch in the bolt holes and drive off the differential ring gear.
4. Using the 2-Jaw Puller and Step Plate, remove the 2 differential bearings.
5. Remove and discard the differential pinion shaft bolt and remove the differential pinion shaft.
6. NOTICE: Due to the spring tension, use care when removing the differential clutch spring or damage to the component may occur.
Remove the differential clutch spring.
7. Remove the differential gears.
1. Remove the 2 differential pinion gears.
2. Remove the 2 differential side gears.
3. Remove the 2 differential pinion thrust washers.
8. NOTE: Keep the differential clutch packs in order. Do not mix them. Always reassemble them in the same sequence.
Separate the differential clutch packs and shims from the differential side gears and tag them "right" and "left."
- Clean and inspect the remaining differential components for wear and damage and install new parts as necessary.
9. NOTE: Do not use acids or solvents when cleaning the differential clutch packs. Wipe the components only with a clean, lint-free cloth.
Clean and inspect the differential clutch packs for wear and damage and install new parts as necessary.
Assembly
1. NOTE: Add 118 ml (4 oz) of friction modifier in the axle.
Using the friction modifier, separate the plates and lubricate each steel clutch plate. Soak all the friction plates for no less than 15 minutes.
2. NOTE: Do not mix the clutch plates, clutch discs or shim from one side with the other.
Assemble the differential clutch packs on their respective differential side gear.
3. Place the base portion of the Differential Clutch Gauge in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool.
4. Position the Differential Clutch Gauge hand-tight on top of the differential clutch pack.
5. Install the Differential Clutch Gauge over the disc and differential clutch pack.
6. Install the nut.
- Tighten to 6.7 Nm (60 lb-in).
7. Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim.
8. Remove the Differential Clutch Gauge from the differential clutch pack and differential side gear assembly.
9. Install the shim(s) on the differential clutch pack and differential side gear assembly.
10. Install the 2 differential side gear assemblies in the differential case.
11. Install the 2 differential pinion gear and differential pinion thrust washer assemblies in the differential case.
12. Using a soft-faced hammer, install the differential clutch spring.
13. Install the differential pinion shaft and install a new bolt finger-tight without tightening into the loctite covered area of the bolt.
14. Mount the differential case and the Differential Clutch Gauge in a vise. Using the Differential Clutch Gauge, check the torque necessary to rotate one differential side gear.
- If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary.
15. Using the Differential Side Bearing Installer, install the 2 differential bearings.
16. Position the differential ring gear and the differential case. Align the bolt holes by starting 2 new bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.
17. Install the 10 new differential ring gear bolts.
- Tighten to 135 Nm (100 lb-ft).
18. Install the differential assembly. For additional information, refer to Differential Case Differential Case.