Dodge Durango (DN). Manual — part 233

(4) Remove the differential side gears and thrust

washers.

ASSEMBLY

(1) Install the differential side gears and thrust

washers.

(2) Install the differential pinion gears and thrust

washers.

(3) Install the pinion mate shaft.
(4) Align the hole in the pinion mate shaft with

the hole in the differential case and install the pinion
mate shaft lock screw.

(5) Lubricate

all

differential

components

with

hypoid gear lubricant.

8 1/4 TRAC-LOK

Y DIFFERENTIAL

The Trac–lok

y differential components are illus-

trated 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

Fig. 43 Trac–lok

Y

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. 42 Pinion Mate Gear Removal

1 – THRUST WASHER
2 – SIDE GEAR
3 – PINION MATE GEAR

3 - 82

8 1/4 AND 9 1/4 AXLE

DN

DISASSEMBLY AND ASSEMBLY (Continued)

replaced. The Trac-lok

y differential can be serviced

with the ring gear installed.

(4) Remove the pinion gear mate shaft lock screw

(Fig. 45).

(5) Remove the pinion gear mate shaft. If neces-

sary, use a drift and hammer (Fig. 46).

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

47).

(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. 44 Differential Case Holding Tool

1 – SIDE GEAR HOLDING TOOL
2 – VISE
3 – DIFFERENTIAL

Fig. 45 Mate Shaft Lock Screw

1 – LOCK SCREW
2 – PINION GEAR MATE SHAFT

Fig. 46 Mate Shaft Removal

1 – PINION MATE SHAFT
2 – SIDE GEAR
3 – DRIFT
4 – PINION MATE GEAR

Fig. 47 Step Plate Tool Installation

1 – SPECIAL TOOL 8140–2
2 – LOWER SIDE GEAR
3 – DIFFERENTIAL CASE

DN

8 1/4 AND 9 1/4 AXLE

3 - 83

DISASSEMBLY AND ASSEMBLY (Continued)

(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.

(13) Rotate differential case until the pinion gears

can be removed.

(14) Remove pinion gears from differential case.

(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 Hold-

ing Tool 8138. Remove side gear, clutch pack retainer,
and clutch pack. Keep plates in correct order during
removal.

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

1 – TORQUE WRENCH
2 – TOOL ASSEMBLED
3 – DIFFERENTIAL CASE

Fig. 50 Remove Pinion Gear Thrust Washer

1 – THRUST WASHER
2 – FEELER GAUGE

Fig. 51 Pinion Gear Removal

1 – PINION GEARS
2 – TOOL

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8 1/4 AND 9 1/4 AXLE

DN

DISASSEMBLY AND ASSEMBLY (Continued)

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.

(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. 52 Side Gear & Clutch Disc Removal

1 – DIFFERENTIAL CASE
2 – RETAINER
3 – SIDE GEAR AND 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

1 – DIFFERENTIAL CASE
2 – LOWER SIDE GEAR AND CLUTCH DISC PACK

DN

8 1/4 AND 9 1/4 AXLE

3 - 85

DISASSEMBLY AND ASSEMBLY (Continued)