Trac-Lok Limited Slip Differential
Fig. 6 Trac-Lok differential exploded view:
Fig. 7 Axle shaft installed in vise to hold differential assembly:
Fig. 8 Removing snap rings from mate 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.
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.
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 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.
Fig. 9 Separating plates and disks:
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 belleville 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.
18. Remove retainer clips from both clutch packs to permit separation of plates and discs.
Fig. 6 Trac-Lok differential exploded view:
Fig. 10 Installing first side gear and clutch pack assembly:
1. Lubricate differential gear teeth, thrust faces, splines and the clutch discs and plates.
2. Assemble clutch packs, placing discs and plates in original position. Then, install retainer clips.
3. Install clutch packs on differential side gears, then install one assembly in case. Ensure clutch packs remain assembled on side gear splines and the retainer clips are fully seated in case pockets.
4. Mount case assembly on axle shaft while clutch packs in place. Ensure that the side gear and axle shaft splines are properly aligned when mounting case on shaft. Also, ensure that the clutch packs are properly assembled in case.
Fig. 11 Installing second side gear and clutch pack assembly:
Fig. 12 Installing pinion mate shaft:
5. Install step plate tool in side gear. Apply a small amount of grease to centering hole of step plate.
6. Install remaining clutch pack and side gear. Ensure clutch packs remain assembled on side gear splines and the retainer clips are fully seated in case pockets.
7. Position gear rotating tool in upper side gear.
8. Hold side gear and gear rotating tool in position and insert forcing screw through top of case and thread into gear rotating tool.
9. Install both differential pinion gears into case, ensuring that gear bores are aligned.
10. Tighten forcing screw to compress belleville springs and provide clearances between teeth of pinion and side gears.
11. Place pinion gears in case and insert rotating tool pawl between side gear teeth. Rotate side gears by pulling on tool handle and install pinion gears. If the side gears will not rotate, adjust belleville spring load. Loosen or tighten forcing screw to permit side gear rotating.
12. Rotate side gears until shaft bores are aligned with case bores.
13. Lubricate pinion gear thrust washers.
14. Tighten or loosen forcing screw to permit thrust washer installation. Install thrust washers using a small screwdriver to guide washers into position. Ensure that the shaft bores in the thrust washers and gears are properly aligned with case bores.
15. Remove forcing screw, gear rotating tool and step plate.
16. Lubricate pinion mate shaft and seat shaft in case using a hammer. Ensure that the snap ring grooves in shaft are exposed to permit snap ring installation.
17. Install pinion mate shaft snap rings.
18. Remove case from axle shaft.
19. Adjust side bearings for zero preload, then install ring gear as outlined for standard differential.