Dana Trac-LOK

Fig. 13 Dana Trac-Lok locking differential exploded view:

Disassembly
1. Place one axle shaft in vise, splined end up, so that splines do not extend more than three inches above jaws of vise.
2. Mount differential case on axle shaft.
3. Using suitable drift, remove roll pin retaining cross pin, then drive out cross pin with hammer and suitable drift, Fig. 13.
4. Position step plate into bottom side gear and lubricate centering hole of step plate.
5. Position gear rotating tool into top side gear.
6. Lubricate threads of forcing screw and thread screw into gear rotating tool, guiding forcing screw into step plate.
7. Tighten forcing screw securely, then, using a piece of .030 inch shim or gauge stock, push out differential spherical washers.
8. Loosen forcing screw momentarily, then tighten forcing screw until a very slight movement of the differential pinion gears is seen.
9. Slide pawl of gear rotating tool between two side gear teeth and pull handle so top side gear rotates, rotating differential pinion gears. Remove differential pinion gears through large openings in case. When attempting to rotate side gear, it may be necessary to tighten or loosen forcing screw to permit gear movement.
10. Manually hold top side gear and clutch pack in case and remove forcing screw, then the gear rotating tool.
11. Remove top side gear and clutch pack, keeping plates and discs in exact order.
12. Turn case so that ring gear side faces up, easing step plate, side gear, and clutch pack out of case.
13. Remove retainer clips from clutch packs, keeping discs and plates in exact order.

Assembly
1. Install side gears and thrust washers in correct order.
2. Lubricate thrust face of side gear and plates and discs with suitable lubricant and assemble plates and discs to side gear splines.
3. Assemble retainer clips to ears of plates, ensuring that clips are completely assembled or seated onto ears of plates.
4. Assemble clutch pack and side gear into case, ensuring that clutch pack stays assembled to side gear splines and that retainer clips are completely seated into pockets of case.
5. Manually retain clutch pack in case, position case on bench, and assemble step plate into side gear, applying small amount of lubricant into centering hole of step plate.
6. Assemble remaining clutch pack and side gear, ensuring that clutch pack stays assembled to side gear splines and that retainer clips are completely seated into pockets of case.
7. Position gear rotating tool into top side gear, manually hold side gear and rotating tool in position, insert forcing screw down through top of case, and thread screw into rotating tool until screw contacts step plate.
8. Position case onto axle shaft by aligning splines of side gear with splines of shaft.
9. Position differential pinion gears opposite one another through openings in case, ensuring that holes of gears are aligned, manually retain gears in position, and tighten forcing screw so that side gears move away from differential pinion gears.
10. Hold differential pinion gears in place and insert pawl of rotating tool between two side gear teeth, then pull on handle so that top side gear rotates and allows differential pinion gears to rotate and enter into case. It may be necessary to slightly tighten or loosen forcing screw to permit gear movement.
11. Put on tool until handle hits case, then remove pawl from between gear teeth and position handle and pawl. Repeat this step until holes of differential pinion gears are perfectly aligned with holes of case.
12. Lubricate both sides of pinion spherical washers with suitable lubricant.
13. Apply torque to forcing screw to obtain installation clearance for spherical washers.
14. Install spherical washers, ensuring that holes of washers and gears are perfectly aligned with holes of case, then remove forcing screw, rotating tool, and step plate.
15. Install pinion shaft in differential case, then the cross shaft locking pin.