Assembly

1. Lubricate differential gear teeth, thrust faces, splines and clutch discs and plates.

Fig. 15 Exploded View Of Trac-Lok Differential:

2. Assemble clutch packs, placing discs and plates in original position. Then, install retainer clips.
3. Mount differential case on axle shaft.

Fig. 17 First Side Gear & Clutch Pack Assembly Installation:

4. Install clutch packs on differential side gears, then install one assembly in lower bore of case. Ensure clutch pack retaining clips remain in position and are seated in case pockets.
5. Install step plate tool on clutch pack assembly. Apply a small amount of grease to centering hole of step plate.

Fig. 18 Second Side Gear & Clutch Pack Assembly Installation:

6. Install remaining clutch pack and side gear. Ensure clutch pack retaining clips remain in position and are seated in case pockets.
7. Hold assembly in position. Insert threaded adapter into top side gear, then insert forcing screw.
8. Tighten forcing screw tool to compress clutch discs.
9. Using turning bar, install both differential pinion gears into case, ensuring gear bores are aligned.
10. Tighten forcing screw to compress conned plates. Install pinion gear thrust washers using a small screwdriver.
11. Remove threaded adapter, forcing screw, turning bar and step plate.

Fig. 19 Pinion Mate Shaft Installation:

12. Install mate shaft into differential case, then secure mate shaft with new roll pin. Stake roll pin to differential case.
13. Remove case from axle shaft.
14. Install ring gear as outlined for standard differential.