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Differential and Driveline » 8 1/4 And 9 1/4 axle » Disassembly and assembly
8 1/4 Trac-loky differential

The Trac-loky differential components are illustrated in (Fig. 43). Refer to this illustration during repair service.

DISASSEMBLY

(1) Clamp Side Gear Holding Tool 8138 in a vise.

(2) Position the differential case on Side Gear Holding Tool 8138 (Fig. 44).

(3) Remove ring gear, if necessary. Ring gear removal is necessary only if the ring gear is to be replaced. The Trac-loky differential can be serviced with the ring gear installed.

(4) Remove the pinion gear mate shaft lock screw (Fig. 45).

Fig. 43 Trac-lokY Differential Components Fig. 43 Trac-lokY Differential Components

1 - THRUST WASHER

2 - PINION

3 - SHAFT LOCK SCREW

4 - PINION MATE SHAFT

5 - SIDE GEAR

6 - RETAINER

7 - DISC

8 - CLUTCH PACK

9 - DIFFERENTIAL CASE

10 - RETAINER

Fig. 44 Differential Case Holding Tool Fig. 44 Differential Case Holding Tool

1 - SIDE GEAR HOLDING TOOL

2 - VISE

3 - DIFFERENTIAL

Fig. 45 Mate Shaft Lock Screw Fig. 45 Mate Shaft Lock Screw

1 - LOCK SCREW

2 - PINION GEAR MATE SHAFT

(5) Remove the pinion gear mate shaft. If necessary, use a drift and hammer (Fig. 46).

(6) Install and lubricate Step Plate 8140-2 (Fig.

47).

Fig. 46 Mate Shaft Removal Fig. 46 Mate Shaft Removal

1 - PINION MATE SHAFT

2 - SIDE GEAR

3 - DRIFT

4 - PINION MATE GEAR

Fig. 47 Step Plate Tool Installation Fig. 47 Step Plate Tool Installation

1 - SPECIAL TOOL 8140-2

2 - LOWER SIDE GEAR

3 - DIFFERENTIAL CASE

(7) Assemble Threaded Adapter 8140-1 into top side gear. Thread Forcing Screw 6960-4 into adapter until it becomes centered in adapter plate.

(8) Position a small screw driver in slot of Threaded Adapter 8140-1 (Fig. 48) to prevent adapter from turning.

(9) Tighten forcing screw tool 122 N*m (90 ft. lbs.) maximum to compress Belleville springs in clutch packs (Fig. 49).

Fig. 48 Threaded Adapter Installation Fig. 48 Threaded Adapter Installation

1 - SOCKET

2 - SLOT IN ADAPTER

3 - SCREWDRIVER

4 - DISC 8140-2

5 - THREADED ROD C-6960-4

6 - THREADED ADAPTER DISC 8140-1

Fig. 49 Tighten Belleville Spring Compressor Tool Fig. 49 Tighten Belleville Spring Compressor Tool

1 - TORQUE WRENCH

2 - TOOL ASSEMBLED

3 - DIFFERENTIAL CASE

(10) Using an appropriate size feeler gauge, remove thrust washers from behind the pinion gears (Fig. 50).

(11) Insert Turning Bar 6960-2 in case (Fig. 51).

(12) Loosen the Forcing Screw 6960-4 in small increments until the clutch pack tension is relieved and the differential case can be turned using Turning Bar 6960-2.

Fig. 50 Remove Pinion Gear Thrust Washer Fig. 50 Remove Pinion Gear Thrust Washer

1 - THRUST WASHER

2 - FEELER GAUGE

(13) Rotate differential case until the pinion gears can be removed.

(14) Remove pinion gears from differential case.

Fig. 51 Pinion Gear Removal Fig. 51 Pinion Gear Removal

1 - PINION GEARS

2 - TOOL

(15) Remove Forcing Screw 6960-4, Step Plate 8140-2, and Threaded Adapter 8140-1.

(16) Remove top side gear, clutch pack retainer, and clutch pack. Keep plates in correct order during removal (Fig. 52).

(17) Remove differential case from Side Gear Holding Tool 8138. Remove side gear, clutch pack retainer, and clutch pack. Keep plates in correct order during removal.

Fig. 52 Side Gear & Clutch Disc Removal Fig. 52 Side Gear & Clutch Disc Removal

1 - DIFFERENTIAL CASE

2 - RETAINER

3 - SIDE GEAR AND CLUTCH DISC PACK

ASSEMBLY

NOTE: The clutch discs are replaceable as complete sets only. If one clutch disc pack is damaged, both packs must be replaced.

Lubricate each component with gear lubricant before assembly.

(1) Assemble the clutch discs into packs and secure disc packs with retaining clips (Fig. 53).

(2) Position assembled clutch disc packs on the side gear hubs.

(3) Install clutch pack and side gear in the ring gear side of the differential case (Fig. 54). Be sure clutch pack retaining clips remain in position and are seated in the case pockets.

(4) Position the differential case on Side Gear Holding Tool 8138.

(5) Install lubricated Step Plate 8140-2 in lower side gear (Fig. 55).

(6) Install the upper side gear and clutch disc pack (Fig. 55).

(7) Hold assembly in position. Insert Threaded Adapter 8140-1 into top side gear.

(8) Insert Forcing Screw 6960-4.

(9) Tighten forcing screw tool to slightly compress clutch discs.

(10) Place pinion gears in position in side gears and verify that the pinion mate shaft holes are aligned.

Fig. 53 Clutch Disc Pack Fig. 53 Clutch Disc Pack

1 - CLUTCH PACK

2 - RETAINER

3 - SIDE GEAR

4 - RETAINER

Fig. 54 Clutch Discs & Lower Side Gear Installation Fig. 54 Clutch Discs & Lower Side Gear Installation

1 - DIFFERENTIAL CASE

2 - LOWER SIDE GEAR AND CLUTCH DISC PACK

(11) Rotate case with Turning Bar 6960-2 until the 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 N*m (90 ft. lbs.) maximum to compress the Belleville springs.

Fig. 55 Upper Side Gear & Clutch Disc Pack Installation Fig. 55 Upper Side Gear & Clutch Disc Pack Installation

1 - UPPER SIDE GEAR AND CLUTCH DISC PACK

2 - DIFFERENTIAL CASE

3 - SPECIAL TOOL 8140-2

(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 6960-4, Step Plate 8140-2, and Threaded Adapter 8140-1.

(15) Install pinion gear mate shaft and align holes in shaft and case.

(16) Install the pinion mate shaft lock screw finger tight to hold shaft during differential installation.

(17) Lubricate all differential components with hypoid gear lubricant.

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    Dodge Durango Service Manual / Differential and Driveline / 8 1/4 And 9 1/4 axle / Disassembly and assembly / 8 1/4 Trac-loky differential

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