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Home >> Dodge and Ram >> 2007 >> RAM 3500 HD Truck 4WD V8-5.7L VIN D >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Service and Repair >> Overhaul >> Rear Axle - 9 1/4 >> Differential-Trac-Lok >> Assembly

Assembly






ASSEMBLY





Clean all components in cleaning solvent and dry components with compressed air. Inspect clutch pack plates for wear, scoring or damage. Replace both clutch packs if any one component in either pack is damaged. Inspect side gears and pinions. Replace any gear that is worn, cracked, chipped or damaged. Inspect differential case and pinion shaft. Replace if worn or damaged.

1. Lubricate each component with gear lubricant before assembly.
2. Assemble clutch discs (1) into packs and secure disc packs with retaining clips (2,4).

NOTE: New Plates and discs with fiber coating (no grooves or lines) must be presoaked for minimum of 20 minutes in Limited Slip Additive before assembly.




3. Position differential case on the Holding Fixture 8136.
4. Position assembled clutch disc packs on the side gear hubs.
5. Install lower side gears (2) with clutch pack in differential case (1).

CAUTION: Verify clutch pack retaining clips are in position and seated in case pockets.




6. Install lubricated disc (3) from Trac-Lok(R) Tool Kit 8139 in lower side gear.
7. Install upper side gear (1) with clutch disc pack in differential case (2).

CAUTION: Verify clutch pack retaining clips are in position and seated in case pockets.

8. Hold assembly in position and install threaded disc from tool kit into top side gear.
9. Install forcing screw from Trac-Lok(R) Tool Kit C-4487 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 (2) until pinion mate shaft holes in pinion gears (1) align with holes in case.

NOTE: 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, Discs and Threaded Adapter.
15. Install pinion gear mate shaft and align holes in shaft and case.
16. Install pinion mate shaft screw.
17. Lubricate all differential components with hypoid gear lubricant.
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