Assembly

TRAC LOK Differential / Rear Axle - 9 1/4 inch

ASSEMBLY
Lubricate each component with gear lubricant before assembly.

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. Assemble the clutch discs into packs and secure disc packs with retaining clips (Fig. 44).
2. Install assembled clutch disc packs on the side gear hubs.






3. Install clutch pack and side gear in the ring gear side of the differential case (Fig. 45). Verify clutch pack retaining clips are in position and seated in the case pockets.
4. Set differential case on Fixture 8138.






5. Install lubricated Disc 8140 without the hole in lower side gear (Fig. 46).
6. Install the upper side gear and clutch disc pack (Fig. 46).
7. Hold assembly in position. Insert Threaded Disc 8140 into top side gear.
8. Install Forcing Screw 6960-4 and tighten screw to slightly compress clutch disc.

9. Place pinion gears in position in side gears and verify that the pinion mate shaft hole is aligned.

10. Rotate case with Turning Bar 6960-2 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.

11. Tighten forcing screw to 122 Nm (90 ft. lbs.) maximum to compress the Belleville springs.

12. 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.

13. Remove forcing screw and discs.
14. Install pinion gear mate shaft and align holes in shaft and case.
15. Install pinion mate shaft lock screw finger tight to hold shaft during differential installation.

16. Lubricate all differential components with hypoid gear lubricant.