9 1/4 Disassembly and Assembly - Trac-Lok Differential

Trac-lok Differential Components:

The Trac-lok differential components are illustrated. Refer to this illustration during repair service.

DISASSEMBLY
1. Clamp Side Gear Holding Tool 8136 in a vise.

Differential Case Holding Tool:

2. Position the differential case on Side Gear Holding Tool 8136.
3. Remove ring gear, if necessary. Ring gear removal is necessary only if the ring gear is to be replaced. The Trac-lok differential can be serviced with the ring gear installed.

Mate Shaft Lock Screw:

4. Remove the pinion gear mate shaft lock screw.

Mate Shaft Removal:

5. Remove the pinion gear mate shaft. If necessary, use a drift and hammer.

Step Plate Tool Installation:

6. Install and lubricate Step Plate 81.39-2.
7. Assemble Threaded Adapter 8139-1 into top side gear. Thread Forcing Screw C-4487-2 into adapter until it becomes centered in adapter plate.

Thraded Adapter Installation:

8. Position a small screw driver in slot of Threaded Adapter 8139-1 to prevent adapter from turning.

Tighten Belleville Spring Compressor Tool:

9. Tighten forcing screw tool 122 Nm (90 ft. lbs.) maximum to compress Belleville springs in clutch packs.

Removal Pinion Gear Thrust Washer:

10. Using an appropriate size feeler gauge, remove thrust washers from behind the pinion gears.

Pinion Gear Removal:

11. Insert Turning Bar C-4487-4 in case.
12. Loosen the Forcing Screw C-4487-2 in small increments until the clutch pack tension is relieved and the differential case can be turned using Turning Bar C-4487-4.
13. Rotate differential case until the pinion gears can be removed.
14. Remove pinion gears from differential case.
15. Remove Forcing Screw C-4487-2, Step Plate 8139-2, and Threaded Adapter 8139-1.

Side Gear & Clutch Disc Removal:

16. Remove top side gear, clutch pack retainer, and clutch pack. Keep plates in correct order during removal.
17. Remove differential case from Side Gear Holding Tool 8136. Remove side gear, clutch pack retainer, and clutch pack. Keep plates in correct order during removal.

ASSEMBLY

NOTE: The clutch discs are replaceable as complete sets only. If one clutch disc pack is damaged, both packs must be replaced.

Lubricate each component with gear lubricant before assembly.

Clutch Disc Pack:

1. Assemble the clutch discs into packs and secure disc packs with retaining clips.
2. Position assembled clutch disc packs on the side gear hubs.

Clutch Discs & Lower Side Gear Installation:

3. Install clutch pack and side gear in the ring gear side of the differential case. Be sure clutch pack retaining clips remain in position and are seated in the case pockets.
4. Position the differential case on Side Gear Holding Tool 8136.

Upper Side Gear & Clutch Disc Pack Installation:

5. Install lubricated Step Plate 8139-2 in lower side gear.
6. Install the upper side gear and clutch disc pack.
7. Hold assembly in position. Insert Threaded Adapter 8139-1 into top side gear.
8. Insert Forcing Screw C-4487-2.
9. Tighten forcing screw tool to slightly compress clutch discs.
10. Place pinion gears in position in side gears and verify that the pinion mate shaft holes are aligned.
11. Rotate case with Turning Bar C-4487-4 until the pinion mate shaft holes in pinion gears align with holes in case. It may be necessary to slightly tighten the forcing screw in order to install the pinion gears.
12. Tighten forcing screw to 122 Nm (90 ft. lbs.) maximum to compress the Belleville springs.
13. Lubricate and install thrust washers behind pinion gears and align washers with a small screw driver. Insert mate shaft into each pinion gear to verify alignment.
14. Remove Forcing Screw C-4487-2, Step Plate 8139-2, and Threaded Adapter 8139-1.
15. Install pinion gear mate shaft and align holes in shaft and case.
16. Install the pinion mate shaft lock screw finger tight to hold shaft during differential installation.
17. Lubricate all differential components with hypoid gear lubricant.