Disassembly

Fig. 1 Two pinion Limited-Slip Differential - Model 44-IFS and Model 60-1U Trac-Loc:

The differential bearings need not be removed to overhaul the limited-slip differential, however, the ring gear will have to be removed first.

To remove and install the side gears, washers and clutch packs during disassembly and assembly requires special procedures and tooling.

For Model 60 use, Limited-Slip Differential Tool D83T-4205-A.

An axle shaft placed in a vise, with the splines extending above the jaws of the vise not more than three inches, makes an excellent holding fixture after the case has been removed from the housing.

1. For Model 441F5 and 60-1 U full float axles, use small drift to remove the roll pin retaining the cross pin. For Model 60-1 U semi-float axles, a lock screw is used to secure the slip fit cross pin.

FIG. 6 Removing Cross Pin From Model 44IFS and 60-1U Axles:

2. Remove the cross pin for the Model 441F5 and 60-1U full float axles with a hammer and drift (Fig. 6). The Model 60-1 U semi-float cross pin is a slip fit and may be lifted out without tools.

FIG. 7 Step Plate in Position:

3. Position the Step Plate, T83T-4205-A4 or equivalent, into the bottom side gear (Fig. 7). Apply grease to the centering hole of the Step Plate.

FIG. 8 Forcing Nut and Forcing Screw in Position:

4. Install Forcing Nut T83T-4205-A2, and Forcing Screw T83T-4205-A3 or equivalents, into the differential case (Fig. 8).

FIG. 9 Guiding Forcing Screw into Step Plate:

5. Guide the forcing screw onto the step plate (Fig.9).

FIG. 10 Removing Spherical Washers:

6. Tighten the forcing screw tightly. This will move the side gears away from the differential pinion gears and relieve the normal loaded condition. Using a piece of 0.762mm (0.030 inch) thick shim or gauge stock, push out the differential spherical washers (Fig. 10).

7. Momentarily, loosen the forcing screw. This step is very important to relieve the pressure of the clutch pack.

8. Re-tighten the forcing screw until a very slight movement of the differential pinion gears is seen.

FIG. 11 Rotating Tool Handle in Position:

9. Insert Handle T83T-4205-A1 or equivalent, into the pinion mate shaft bore and rotate the case (Fig. 11). Continue this until the differential pinion gears can be removed through the large openings in the case. When attempting to rotate the side gear, some tightening or loosening of the forcing screw will probably be required to permit the gear movement.

FIG. 12 Holding Clutch Pack:

10. Retain the top side gear and clutch pack in the case with the hand and remove the forcing screw. Continue to hold the side gear and clutch pack and remove the gear rotating tool (Fig. 12). Remove the top side gear and clutch pack. Keep the stack of plates and discs in exact order.

11. Turn this case so the flange, or ring gear side is up. As this is done, ease the step plate, side gear and clutch pack out of the case.

FIG. 13 Model 60-1U Plates and Discs to Side Gear-Exploded View:

12. Remove the retainer clips from both clutch packs to allow separation of the discs and plates for cleaning and inspection. Be sure to keep them in the exact order (Fig. 13).