Dana Power-LOK

Fig. 12 Dana Powr-Lok locking differential exploded view:

Disassembly
1. Scribe a mark between the differential case halves to be used during assembly. Also, mark the pinion mate shafts and corresponding ramps for assembly in original locations.
2. Clamp differential assembly in a soft jaw vise.
3. Loosen but do not remove the case half retaining bolts, Fig. 12.
4. Place assembly on bench with the ring gear half down and remove case half retaining screws.
5. Remove the cover half of the case.
6. Remove upper mate shaft, side gear, side gear ring and clutch pack. Retain parts with cover half of case so they can be installed in original position.
7. Remove lower mate shaft, side gear, side gear ring and clutch pack from drive gear case half.

Assembly
1. Place side gear ring from ring gear half of case on a pinion flange or other suitable fixture so the case is approximately 4 inches above bench.
2. Lubricate clutch plates and assemble clutch pack on side gear ring.
3. Place ring gear side of case over clutch pack and side gear ring. Ensure that the clutch plate lugs enter the slots in the case and that the case bottoms on the clutch pack.
4. Invert the assembly. Hold assembly together while inverting.
5. Install the ring gear case half side gear in side gear ring.
6. Install axle shaft spacer in cross shaft.
7. Install the ring gear case half pinion mate shaft and pinions on the side gear ring.
8. Install the cover half pinion mate shaft and pinions.
9. Place side gear on pinions, then the side gear ring on side gear.
10. Assemble clutch pack on side gear ring, aligning clutch pack lugs.
11. Install cover half of case over assembly, aligning the marks made during disassembly.
12. Install the case half retaining bolts, turning the bolts to engage a few threads only.
13. Insert axle shaft into assembly and align the splines of the side gears and side gear rings. With the axle shafts in position, torque case half retaining bolts to 65---70 ft. lbs.
14. Remove axle shafts.
15. If the differential has been assembled properly, each pinion mate cross shaft should be tight on its ramp. However, if clearance is present, it should not exceed .010 inch and be equal at all four cross shaft ends.