Dodge ram truck 3500 1996 Service Manual page 170

3 - 114 DIFFERENTIAL AND DRIVELINE
mm
D I S A S S E M B L Y A N D A S S E M B L Y (Continued)
CLUTCH PACK
RETAINER
RETAINER
SIDE G E A R
J8903-50
Fig. 57 dutch Disc Pack
(4) Install clutch pack and side gear in lower bore
(Fig. 58). Be sure clutch pack retaining clips
remain in position and are seated in the case
pockets.
DIFFERENTIAL
CASE
LOWER
SIDE GEAR
AND
CLUTCH DISC
PACK
J9003-4
Fig. 58 Clutch Discs & Lower Side Gear Installation
(5) Install lubricated Step Plate C-4487-1 on first
clutch pack (Fig. 59).
(6) Install the upper side gear and clutch disc pack
(Fig. 59).
(7) Hold assembly in position. Insert Threaded
Adapter C-4487-3 into top side gear, insert forcing
Screw C-4487-2.
(8) Tighten forcing screw tool to slightly compress
clutch discs.
(9) Place pinion gears in position in side gears and
verify that mate shaft hole line up.
UPPER SIDE
GEAR A N D CLUTCH
DISC PACK
DIFFERENTIAL
CASE
SPECIAL TOOL
C-4487-1
J9203-6
Fig. 59 Upper Side Gear & Clutch Disc Pack
Installation
(10) Rotate case with Turning Bar C-4487-4 until
mate shaft holes in pinion gears align with holes in
case.
(11) Tighten forcing screw to 122 N-m (90 ft. lbs.)
to compress the Belleville springs. 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.
(12) Remove forcing screw, threaded adapter and
step plate. Install pinion gear mate shaft, align holes
in shaft and case.
(13) Install the pinion mate shaft lock screw finger
tight to hold shaft during installation.
If replacement gears and thrust washers were
installed, it is not necessary to measure the
gear backlash. Correct fit is due to close
machining tolerances during manufacture.
(14) Lubricate all differential components with
hypoid gear lubricant.
POWER-LOK—MODEL 70/TRAC-LOK—MODEL 80
The Trac-Lok differential for the Model 80 axle
looks like the Power-Lok differential for the Model 70
axle but their are differences.
The Model 80 Trac-Lok differential has a one-piece
cross shaft and uses 6 disc and 5 plates for each
clutch pack. Only one disc in each clutch pack is
dished.
The Model 70 Power-Lok differential has a two-
piece cross shaft and uses 2 disc and 3 plates for
each clutch pack. All disc are dished i n this unit.