Differential - TRAC-LOK

Fig 1: Clutch Pack

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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.

Lubricate components with gear lubricant.
Assemble clutch discs (1), plates (6) and Belleville spring (2) into packs and secure disc packs with retainers (5).
NOTE: Belleville spring (2) is position with the convex side against the side gear.
Position assembled clutch disc packs on the side gear (4) hubs.

Fig 2: Lower Side Gear
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Install lower clutch pack and side gear (1) in the differential case (2), with retaining clips seated in the case pocket.

Fig 3: Upper Side Gear
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Install upper clutch disc pack (1) retaining clips (2) and side gear (3) with seated in the case pocket.

Fig 4: Pinion Gears
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Lubricated and install discs into side gears from Trac-lok® Tool C-4487. Install forcing screw from Trac-lok® Tool C-4487 and thread screw to compress Belleville springs in clutch packs.
Install pinion gears (2) in side gears opposite each other.

Fig 5: Turning Bar
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Rotate differential case (2) with turning bar (1) from Trac-lok® Tool C-4487 until pinion gears align with mate shaft holes in the case.
NOTE: Loosen forcing screw in small increments to relieve clutch pack tension if differential case can not be rotated.

Fig 6: Thrust Washer
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Install pinion gear thrust washers (1) between the gear and case (2). Align washers with mate shaft hole in the case.

Fig 7: Lower Disc
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Remove forcing screw upper disc from side gear.
Remove lower disc (1) from side gear (2).

Fig 8: Mate Shaft
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Install pinion mate shaft (3) in case (1).

Fig 9: Lock Pin
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Install pinion mate shaft (1) roll pin (2).
Install ring gear.
Lubricate all differential components with gear lubricant.