Disassembly and Assembly - Trac-Lok

DISASSEMBLY





1. Clamp side gear Holding Fixture 6965 in a vise and position the differential case on the Holding Fixture (Fig. 32).
2. Remove ring gear if the ring gear is to be replaced. The Trac-lok differential can be serviced with the ring gear installed.
3. Remove pinion shaft roll pin.





4. Remove pinion shaft with a drift and hammer (Fig. 33).





5. Install and lubricate Step Plate C-6960-3 (Fig. 34).
6. Assemble Threaded Adapter C-6960-1 into top side gear. Thread Forcing Screw C-6960-4 into adapter until it becomes centered in adapter plate.





7. Position a small screw driver in slot of Threaded Adapter Disc C-6960-3 (Fig. 35) to prevent adapter from turning.





8. Install Forcing Screw C-6960-4 and tighten screw to 122 Nm (90 ft. lbs.) maximum to compress Belleville springs in clutch packs (Fig. 36).





9. With a feeler gauge remove thrust washers from behind the differential pinion gears (Fig. 37).





10. Insert Turning Bar C-6960-2 into the pinion shaft hole in the case (Fig. 38).
11. Loosen the Forcing Screw in small increments until the clutch pack tension is relieved and the differential case can be turned using Turning Bar.
12. Rotate differential case until the pinion gears can be removed.
13. Remove pinion gears from differential case.
14. Remove Forcing Screw, Step Plate and Threaded Adapter.





15. Remove top side gear, clutch pack retainer and clutch pack. Keep plates in correct order during removal (Fig. 39).
16. Remove differential case from the Holding Fixture. Remove side gear, clutch pack retainer and clutch pack. Keep plates in correct order during removal.

ASSEMBLY
Clean all components in cleaning solvent. 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.
Lubricate each component with gear lubricant before assembly.





1. Assemble the clutch discs into packs and secure disc packs with retaining clips (Fig. 40).

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.

2. Position 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. 41). Be sure clutch pack retaining clips remain in position and are seated in the case pockets.
4. Position the differential case on the Holding Fixture 6965.





5. Install lubricated Step Plate C-6960-3 in lower side gear (Fig. 42).
6. Install the upper side gear and clutch disc pack (Fig. 42).
7. Hold assembly in position. Insert Threaded Adapter C-6960-1 into top side gear.
8. Install Forcing Screw C-6960-4 and tighten screw to slightly compress clutch disc.
9. Place differential pinion gears in position in side gears and verify that the pinion shaft hole is aligned.
10. Rotate case with Turning Bar C-6960-2 until the pinion 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 pinion shaft into each pinion gear to verify alignment.
13. Remove Forcing Screw, Step Plate and Threaded Adapter.
14. Install pinion shaft and align holes in shaft and case.
15. Install and seat pinion shaft roll pin in differential case. Peen the edge of the roll pin hole in the case slightly in two places 180° apart.
16. Lubricate all differential components with hypoid gear lubricant.