Diagnosis And Testing: Disassembly

WARNING: This page is about a different car, the 2004 Dodge Dakota and 2003 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.

Clamp side gear Fixture 8138 in a vise and set differential case on the Fixture (Fig 1 ).

Fig 1: Differential Case Fixture
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Remove ring gear if the ring gear is to be replaced. The Trac-lok° differential can be serviced with the ring gear installed.
Remove pinion gear mate shaft lock screw (Fig 2 ).

Fig 2: Removing Mate Shaft Lock Screw
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Remove pinion gear mate shaft with a drift and hammer.
Install Discs 81440 without threaded hole in the lower side gear (Fig 3 ).

Fig 3: Installing Lower Disc
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Install Threaded Disc 8140 in the upper side gear. Thread Forcing Screw 6960-4 into threaded disc until it becomes centered in other disc.
Insert a screw driver in slot of threaded disc (Fig 4 ) to prevent disc from turning.

Fig 4: Inserting A Screw Driver In Slot Of Threaded Disc
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Tighten forcing screw to 122 N.m (90 ft. lbs.) maximum to compress Belleville springs in clutch packs (Fig 5 ).

Fig 5: Compressing Belleville Spring
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With a feeler gauge remove thrust washers from behind the pinion gears (Fig 6 ).

Fig 6: Removing Pinion Gear Thrust Washer
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Insert Turning Bar 6960-2 into the pinion mate shaft hole in the case (Fig 7 ).

Fig 7: Inserting Turning Bar 6960-2 Into Pinion Mate Shaft Hole In Case
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Loosen the Forcing Screw in small increments until the clutch pack tension is relieved and the differential case can be turned using Turning Bar.
Rotate differential case until the pinion gears can be removed.
Remove pinion gears from differential case.
Remove Forcing Screw, Step Plate and Threaded Adapter.
Remove top side gear, clutch pack retainer and clutch pack. Keep plates in order during removal (Fig 8 ).

Fig 8: Side Gears And Clutch Discs
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Remove differential case from the fixture. Remove side gear, clutch pack retainer and clutch pack. Keep plates in order during removal.