Assembly

Rear Axle - 248RBI / DIFFERENTIAL w/TRAC-LOC

ASSEMBLY
1. Lubricate each component with gear lubricant before assembly.





2. Assemble the clutch discs into packs and secure disc packs with retaining clips (Fig. 44).

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.

3. Position assembled clutch disc packs on the side gear hubs.





4. Install clutch pack and side gear in the ring gear side of the differential case (Fig. 45). Be sure clutch pack retaining clips remain in position and are seated in the case pockets.
5. Position the differential case on the Holding Fixture 6965.





6. Install lubricated Step Plate C-6960-3 in lower side gear (Fig. 46).
7. Install the upper side gear and clutch disc pack (Fig. 46).
8. Hold assembly in position. Insert Threaded Adapter C-6960-1 into top side gear.
9. Install Forcing Screw C-6960-4 and tighten screw to slightly compress clutch disc.
10. Place pinion gears in position in side gears and verify that the pinion mate shaft hole is aligned.
11. Rotate case with Turning Bar C-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.
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, Step Plate and Threaded Adapter.
15. Install pinion gear mate shaft and align holes in shaft and case.
16. Install pinion mate shaft roll pin. Peen the edge of the roll pin hole in the case slightly in two places 180° apart.
17. Lubricate all differential components with hypoid gear lubricant.