Chrysler RAM TRUCK 2500 1994 Service Manual page 156

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REAR SUSPENSION AND AXLE 3 - 41
F L A N G E B U T T O N BOLTS
P I N I O N
M A T E S H A F T J9203-71
Fig. 17 Power-Lok Differential
Fig. 18 Case Marked
(2) Inspect clutch pack plates for wear, scoring or
damage. Replace both clutch packs i f any one compo­
nent i n either pack is damaged.
(3) Inspect side and pinion gears. Replace any gear
that is worn, cracked, chipped or damaged.
(4) Inspect differential case and pinion shaft. Re­
place i f worn or damaged.
CLUTCH
PLATES
BUTTON
HALF
FLANGE
HALF
Fig. 19 Cover Half Removal
ASSEMBLY
(1) The clutch discs are replaceable as complete
sets only. I f one clutch disc pack is damaged,
both packs must be replaced. Lubricate each com­
ponent with gear lube before assembly and installa­
tion.
(2) Saturate the clutch plates with Hypoid Gear
Lubricant or Additive. Assemble clutch packs into the
side gear plate i n exactly the same position as re­
moved (Fig. 21).
(3) Line up the plate ears and install the assem­
bled pack into the flange half (Fig. 22). Make sure
the clutch plate lugs enter the slots i n the case.
Also make sure the clutch pack bottoms out on
the case.
(4) Install pinion mate shafts and pinion mate
gears (Fig. 23).Make sure shafts are correctly in­
stalled according to the alignment marks.
(5) Lubricate and install the other side gear and
clutch pack as done above i n Step 3.
(6) Correctly align and assemble button half to
flange half. Install case body screws finger tight.
(7) Tighten body screws alternately and evenly.
Tighten screws to 89-94 N-m (65 to 70 ft. lbs.) torque
(Fig. 24).
I f bolt heads have 7 radial lines stamped on the
head, tighten these to 122-136 N-m (90 to 100 ft. lbs.)
torque.