Disassembly

Fig. 12 Measuring axle shaft:

1. Mount one axle shaft in a vise with the splined end facing upward. Do not allow end of shaft to extend more than 2-3/4 inch above top of vise. This prevents the shaft from fully entering the side gear.
2. Mount differential case on axle shaft with ring gear bolt heads facing upward.

Fig. 13 Exploded view of Trac-Lok differential:

3. Remove ring gear bolts.
4. Loosen ring gear with a mallet, remove case from axle shaft, then the ring gear.
5. Remount differential case on axle shaft.

Fig. 14 Removing snap rings from mate shaft:

6. Remove snap rings from pinion mate shaft using two screwdrivers to disengage snap rings.
7. Remove pinion mate shaft with a suitable drift and hammer. The gear rotating tool J-23781 or equivalent is required to perform the following steps. The tool consists of three parts: gear rotating tool, forcing screw and step plate.
8. Install step plate in lower differential side gear.
9. Position pawl end of gear rotating tool on step plate.
10. Insert forcing screw through top of case and thread into gear rotating tool. Apply a small amount of grease to centering hole in step plate and oil forcing screw threads before using forcing screw.
11. Center forcing screw in step plate and tighten screw to move differential side gears away from pinion gears.
12. Remove pinion gear thrust washers with a 0.030 feeler gauge or shim stock. Insert gauge or shim stock between washer and case and withdraw thrust washer and gauge. Momentarily, loosen the forcing screw. This step is very important to relieve the pressure of the clutch pack.
13. Tighten forcing screw until movement of pinion gears is observed.
14. Insert pawl end of gear rotating tool between teeth of one differential side gear. Pull handle of tool to rotate side and pinion gears. Remove the pinion gears as gears appear in case opening. It may be necessary to adjust the tension applied on the bevelled springs by the forcing screw before the gears can be rotated in the case.
15. Retain upper side gear and clutch pack in case by holding bottom of rotating tool while removing forcing screw. Remove rotating tool, upper side gear and clutch pack.
16. Remove differential case from axle shaft.
17. Invert case with flange or ring gear side facing upward and remove step plate tool, lower side gear and clutch pack.

Fig. 15 Separating plates & discs:

18. Remove retainer clips from both clutch packs to permit separation of plates and discs.