Differential Case and Ring Gear- Traction-LOK(R)

Differential Case and Ring Gear- Traction-Lok(R)





Special Tool(s)





Material

Disassembly
1. Remove the differential assembly from the axle assembly.





2. Remove and discard the differential pinion shaft lock bolt, then remove the differential pinion shaft.





3. Remove the differential clutch spring.





4. Remove the differential gears.
1 Remove the 2 differential pinion gears and differential pinion gear thrust washers.
2 Remove the 2 differential side gears with the differential clutch packs and the shims and tag them "left" and "right."





5. CAUTION: Keep the differential clutch packs in order. Do not mix them. Always reassemble them in the same sequence.

CAUTION: Do not use acids or solvents when cleaning the differential clutch packs. Wipe the components only with a clean, lint-free cloth.

Remove the differential clutch packs and shims from the differential side gears.
^ Clean and inspect the differential clutch packs for wear and damage. Clean and inspect the remaining differential components for wear and damage. Install new components as necessary.

Assembly





1. Lubricate each steel differential clutch plate with friction modifier and soak all differential clutch discs for no less than 15 minutes.
^ Use friction modifier.





2. CAUTION: Do not mix the differential clutch plates, differential clutch discs or shims from one side with the other.

Assemble the differential clutch packs (without the shims) on their respective differential side gear.





3. Place the base portion of the special tool in a vise, then install the differential clutch pack and differential side gear (without the shim).





4. Install the special tool hand-tight on top of the differential clutch pack.





5. Install the special tool over the disc and differential clutch pack.





6. Install the nut for the special tool.
^ Tighten to 7 Nm (60 inch lbs.).





7. Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new shim.





Select Shims

8. Remove the special tool from the differential clutch pack and differential side gear assembly.
9. Install the shim(s) on the differential clutch pack and differential side gear assembly.





10. Install the differential side gear assemblies in the differential assembly.
11. Install the differential pinion gears and the differential pinion gear thrust washers.





12. Using a soft-faced hammer, install the differential clutch spring.





13. NOTE: IF a new differential pinion shaft lock bolt is unavailable, coat the threads with threadlock and sealer.

Install the differential pinion shaft and install a new differential pinion shaft bolt.
^ Tighten to 30 Nm (22 ft. lbs.).





14. Mount the differential assembly and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
^ If reusing the original differential clutch packs, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new differential clutch packs may vary.
15. Install the differential assembly into the axle assembly.