Trac-Lok Differential Carrier - Disassembly

DISASSEMBLY





1. Remove ring gear.
2. Clamp side gear Fixture 6963A (1) in a vise and set differential case (2) on the fixture.





3. Remove pinion gear mate shaft roll pin from differential case (1) with a hammer and punch (2).





4. Rotate differential case (1) on the fixture (2) and remove pinion mate shaft (3).





5. Lubricate and install disc (1) without threaded hole from Trac-lok(R) Tool C-4487 into lower side gear (2).





6. Lubricate and install disc (1) with threaded hole from Trac-lok(R) Tool C-4487 into upper side gear (2). Thread forcing screw (3) from Trac-lok(R) Tool C-4487 into upper disc until it contacts the lower disc (4). NOTE: Slot in threaded upper disc (1) can be used to prevent it from turning using a screw driver.






7. Tighten forcing screw to compress belleville springs in clutch packs. Then Insert turning bar (1) from Trac-lok(R) Tool C-4487 into the pinion mate shaft hole in the case (2).





8. Rotate differential case (1) with turning bar until the pinion gears (1) and washers can be removed. NOTE: Loosen forcing screw in small increments to relieve clutch pack tension if differential case can not be rotated.






9. Remove Forcing Screw, Step Plate and Threaded Adapter.
10. Remove upper clutch pack (1), clutch pack retainers (2) and upper side gear (3) from case.





11. Remove lower clutch pack, clutch pack retainers and lower side gear (1) from case (2).





12. Remove clutch pack retainers (1), clutch pack (3) belleville spring (2) from side gear (4). Keep plates in order during removal.