Trac-Lok - Locking Differential: Overhaul Dodge Durango I

Disassembly (Except 286 RBI)

1. Place appropriate side gear holding tool in soft-jaw vise. Position differential carrier on holding tool. Remove ring gear, if necessary. Ring gear removal is only necessary when ring gear is being replaced.
2. Remove roll pin holding pinion mate shaft into housing. Remove pinion gear mate shaft. A drift and hammer can be used if necessary. (Scheme 4)
3. Install appropriate step plate on lower side gear. Install appropriate threaded forcing screw into upper side gear. (Scheme 5)
4. Thread forcing screw into threaded adapter disc until forcing screw is centered in threaded adapter disc. Perform STEP 1 shown in illustration. (Scheme 5)
5. Place small screwdriver in slot of threaded adapter disc to prevent disc from rotating. Tighten forcing screw to relieve tension from clutch pack.
6. Remove pinion gear thrust washers. Loosen forcing screw to release pressure from clutch pack. Install appropriate turning bar in hole on side of differential case. Perform STEP 2 shown in illustration. (Scheme 5)
7. Using turning bar, rotate differential case until pinion gears can be removed. Remove pinion gears. Remove turning bar, forcing screw, step plate, and threaded adapter disc from differential case.
8. Remove upper side gear and clutch pack. (Scheme 4) Remove differential case from axle shaft. Remove remaining side gear and clutch pack from differential case.
9. Remove clutch pack retainers from clutch pack. Keeping clutch pack components in correct order, disassemble clutch pack.

Scheme 4

Scheme 5

Disassembly (286 RBI)

Note. Mark clutch pack location for reassembly reference. Note positions of clutch pack components before removing clutch pack retainers. Clutch packs must be assembled in correct order and installed in original location.

1. Mark ring gear half and cover half for installation reference. Remove case bolts and button cover half. Remove upper side gear clutch ring, upper side gear and clutch pack. (Scheme 6)
2. Remove same parts from ring gear half of case.

Scheme 6

Reassembly (Except 286 RBI)

1. Lubricate clutch pack components with gear lube. Reassemble clutch packs. Ensure components are installed in correct sequence and in original location. (Scheme 4) Install clutch pack retainers onto clutch packs.
2. Install clutch packs onto respective side gears. Install differential case onto axle shaft. Install clutch pack and lower side gear into differential case.
3. Install step plate onto lower side gear. Install upper side gear and clutch pack into differential case. Install threaded adapter disc into upper side gear. Install forcing screw.
4. Tighten forcing screw to compress clutch packs. Install pinion gears onto side gears. Using turning bar, rotate differential case until hole in differential case is aligned with pinion gears. Remove turning bar.
5. Lubricate pinion gear thrust washers with gear lube. Install pinion gear thrust washers. It may be necessary to tighten forcing screw until pinion gear thrust washers can be installed.
6. Remove forcing screw, step plate and threaded adapter disc. Using soft-face hammer, tap pinion shaft into differential case. Install snap rings onto pinion shaft (if equipped).
7. Install NEW roll pin. Stake differential case in 2 areas to retain roll pin. Remove differential case from axle shaft. Install ring gear onto differential case. Install NEW ring gear bolts. DO NOT reuse bolts. Tighten ring gear bolts evenly in alternating pattern to specification. See «TORQUE SPECIFICATIONS»(ref-97859-S24411576772001051100000).

Reassembly (286 RBI)

1. Lubricate clutch pack components with gear lube. Reassemble clutch pack into side gear plate. Ensure components are installed in correct sequence and in original location. (Scheme 6)
2. Align plate ears and install assembled clutch pack into flange half. Ensure clutch plate lugs enter slots in case and that clutch pack bottoms out into case.
3. Lubricate and install other side gear and clutch pack.
4. Align and assemble button half to flange half. Tighten body screws evenly in alternating pattern to specification. See «TORQUE SPECIFICATIONS»(ref-97859-S24411576772001051100000).