Differential Case Assembly

EXC. TRACTION-LOK LIMITED SLIP DIFFERENTIAL
1. On 6.75 inch axles, apply suitable axle lubricant to components, then proceed as follows:
a. Place side gears and thrust washers in differential case, then place pinion gears and thrust washers in case exactly opposite each other in the case opening and in mesh with the side gears.
b. Rotate pinions and thrust washers until pinion gear holes align with pinion shaft holes in the case.
c. Install pinion shaft in case while aligning pinion shaft lock pin hole with hole in case, then install lock pin.
d. Position lefthand case on righthand case, then align reference marks and press two halves together in suitable vise.
e. Install ring gear on case and install new bolts. If bolts show a green coating on the threaded area, install bolts as is and torque to 45---60 ft. lbs. If no coating is noticed, coat bolt threaded area with suitable thread locking compound, then install bolts and torque to 45---60 ft. lbs.
2. On all except 6.75 inch axles, install replacement ring gear (if removed). Apply suitable locking compound to new bolts and torque to 70---85 ft. lbs.

Fig. 8 Pinion gear removal & installation. Ford Traction-Lok:

TRACTION-LOK LIMITED SLIP DIFFERENTIAL
Ford Type
1. Apply suitable lubricant to clutch plates, then install left side gear, clutch pack and new shim into differential case. Repeat procedure for righthand side.
2. Install pinion gears and thrust washers 180° apart and in contact with side gears.
3. Align gears with pinion shaft bore, Fig. 8, using 12 inch socket extension inserted in pinion shaft rotator.
4. Install ``S'' shaped preload spring into differential using soft faced hammer.

Fig. 5 Borg Warner Traction-Lok exploded view:

Borg-Warner Type
1. Place case cap half in vise with cavity facing upward.
2. Install cone and side gear in reverse order of removal, Fig. 5.
3. Assemble remaining parts in proper order, Fig. 5.
4. Install case flange half over top cone and side gear. Install and snug tighten two retaining bolts on either side of case.
5. Place differential case in suitable vise, then tighten vise to overcome spring preload tension.
6. Install remaining bolts and torque evenly to 34---39 ft. lbs. Case cap bolts and case thread holes must be clean and free of oil to assure proper torque readings.
7. Apply Loctite or equivalent to pinion lock bolt and install. Torque bolt to 15---30 ft. lbs.