Disassembly and Assembly - Trac-Lok
DIFFERENTIAL TRAC LOKDISASSEMBLY
1. Clamp side gear Fixture 6965 in a vise and set differential case on the fixture (Fig. 50).
NOTE: The TRAC-lok- differential can be serviced with the ring gear installed unless the gear hangs over the pinion shaft, then it must be removed.
2. Remove pinion gear mate shaft roll pin with a hammer and punch.
3. Remove pinion gear mate shaft with a drift and hammer.
4. Lubricate and install disc without threaded hole from TRAC-lok- Tool C-4487 into lower side gear (Fig. 51).
5. Lubricate and install disc with threaded hole from TRAC-lok- Tool C-4487 into upper side gear. Thread forcing screw from tool into threaded disc until it becomes centered in lower disc.
6. Position a small screw driver in slot of the threaded disc (Fig. 52) to prevent adapter from turning.
7. Tighten forcing screw to 122 Nm (90 ft. lbs.) maximum to compress Belleville springs in clutch packs (Fig. 53).
8. With a feeler gauge remove thrust washers from behind the pinion gears (Fig. 54).
9. Insert turning bar from tool into the pinion mate shaft hole in the case (Fig. 55).
10. Loosen forcing screw in small increments until clutch pack tension is relieved and the differential case can be turned using turning bar.
11. Rotate differential case until the pinion gears can be removed.
12. Remove pinion gears from differential case.
13. Remove Forcing Screw, Step Plate and Threaded Adapter.
14. Remove top side gear, clutch pack retainer and clutch pack. Keep plates in order during removal (Fig. 56).
15. Remove differential case from the Holding Fixture. Remove side gear, clutch pack retainer and clutch pack. Keep plates in order during removal.
ASSEMBLY
NOTE: New Plates and discs with fiber coating (no grooves or lines) must be presoaked in Friction Modifier before assembly. Soak plates and discs for a minimum of 20 minutes.
1. Lubricate components with gear lubricant.
2. Assemble clutch discs into packs and secure disc packs with retaining clips (Fig. 57).
NOTE: Dished plate is position with the convex side against the side gear.
3. Position assembled clutch disc packs on the side gear hubs.
4. Install clutch pack and side gear in the ring gear side of the differential case, with retaining clips seated in the case pockets (Fig. 58).
5. Position the differential case on the Holding Fixture 6965.
6. Lubricated and install disc without threaded hole from TRAC-Lok- Tool C-4487 into lower side gear.
7. Install upper side gear and clutch disc pack with retaining clips seated in the case pockets (Fig. 59).
8. Hold assembly in position and install threaded disc from TRAC-Lok- Tool C-4487 into top side gear.
9. Install forcing screw and tighten screw to slightly compress clutch disc.
10. Place pinion gears in position in side gears and verify that the pinion mate shaft hole is aligned.
11. Rotate case with turning bar C-4487-2 until pinion mate shaft holes in pinion gears align with holes in case. It may be necessary to slightly tighten the forcing screw in order to install the pinion gears.
12. Tighten forcing screw to 122 Nm (90 ft. lbs.) maximum to compress the Belleville springs.
13. Lubricate and install thrust washers behind pinion gears and align washers with a small screw driver. Insert mate shaft into each pinion gear to verify alignment.
14. Remove Forcing Screw, Step Plate and Threaded Adapter.
15. Install pinion gear mate shaft and align holes in shaft and case.
16. Install pinion mate shaft roll pin. Stake (peen) case over pin in two places 180 degrees apart.
17. Lubricate all differential components with hypoid gear lubricant.