Dodge 2000 DURANGO Service Manual page 135

DN
DISASSEMBLY AND ASSEMBLY (Continued)
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 com-
plete 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.
8 1/4 AND 9 1/4 AXLE
Fig. 53 Clutch Disc Pack
1 – CLUTCH PACK
2 – RETAINER
3 – SIDE GEAR
4 – RETAINER
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.
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