Dodge Dakota (R1). Manual — part 212
DISASSEMBLY
(1) Remove pinion shaft lock screw (Fig. 27).
(2) Remove pinion shaft.
(3) Rotate differential side gears and remove the
differential pinions and thrust washers (Fig. 28).
(4) Remove the differential side gears and thrust
washers.
ASSEMBLY
(1) Install differential side gears and thrust wash-
ers.
(2) Install differential pinion and thrust washers.
(3) Install the pinion shaft.
(4) Align the hole in the pinion shaft with the hole
in the differential case and install the pinion shaft
lock screw.
(5) Lubricate
all
differential
components
with
hypoid gear lubricant.
Fig. 25 Reference Mark
1 - REFERENCE MARKS
2 - REFERENCE MARKS
3 - DIFFERENTIAL HOUSING
4 - BEARING CAP
Fig. 26 Threaded Adjuster
1 - AXLE TUBE
2 - BACKING PLATE
3 - THREAD ADJUSTER WRENCH
Fig. 27 Pinion Shaft Lock Screw
1 - LOCK SCREW
2 - PINION SHAFT
Fig. 28 Differential
1 - THRUST WASHER
2 - SIDE GEAR
3 - DIFFERENTIAL PINION
3 - 66
REAR AXLE - 8 1/4
AN
DIFFERENTIAL (Continued)
INSTALLATION
(1) Apply a coating of hypoid gear lubricant to the
differential bearings, bearing cups, and threaded
adjusters. A dab of grease can be used to keep the
adjusters in position. Carefully position the assem-
bled differential case in the housing.
(2) Install the differential bearing caps in their
original locations (Fig. 29).
(3) Install bearing cap bolts and tighten the upper
bolts to 14 N·m (10 ft. lbs.). Tighten the lower bolts
finger-tight until the bolt head is seated.
(4) Perform the differential bearing preload and
adjustment procedure.
(5) Tighten bearing cap bolts to 95 N·m (70 ft.lbs).
(6) Install adjuster locks on the bearing caps.
(7) Install axle shafts.
(8) Apply a bead of Mopar Silicone Rubber Sealant
or equivalent to the housing cover (Fig. 30).
Install the housing cover within 5 minutes
after applying the sealant.
(9) Install the cover and any identification tag.
Tighten the cover bolts to 41 N·m (30 ft. lbs.) torque.
(10) Fill differential with gear lubricant to bottom
of the fill plug hole. Refer to the Lubricant Specifica-
tions for correct quantity.
(11) Install the fill hole plug.
(12) Install wheel and tire assemblies.
(13) Remove support and lower vehicle.
(14) Trac-lok
y
differential
equipped
vehicles
should be road tested by making 10 to 12 slow figure-
eight turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat-
ter noise complaint.
DIFFERENTIAL - TRAC-LOK
DIAGNOSIS AND TESTING - TRAC-LOK
Y
The most common problem is a chatter noise when
turning corners. Before removing a Trac-lok
y unit
for repair, drain, flush and refill the axle with the
specified lubricant. A container of Mopar Trac-lok
y
Lubricant (friction modifier) should be added after
repair service or during a lubricant change.
After changing the lubricant, drive the vehicle and
make 10 to 12 slow, figure-eight turns. This maneu-
ver will pump lubricant through the clutches. This
will correct the condition in most instances. If the
chatter persists, clutch damage could have occurred.
DIFFERENTIAL TEST
The differential can be tested without removing the
differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 or
equivalent tool to studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 31).
(6) If rotating torque is less than 22 N·m (30 ft.
lbs.) or more than 271 N·m (200 ft. lbs.) on either
wheel the unit should be serviced.
Fig. 29 Bearing Caps & Bolts
1 - REFERENCE MARKS
2 - REFERENCE MARKS
3 - DIFFERENTIAL HOUSING
4 - BEARING CAP
Fig. 30 Differential Cover Sealant
1 - SEALANT
2 - DIFFERNTIAL COVER
AN
REAR AXLE - 8 1/4
3 - 67
DIFFERENTIAL (Continued)
DISASSEMBLY
(1) Clamp side gear Holding Fixture 6965 in a vise
and position the differential case on the Holding Fix-
ture (Fig. 32).
(2) Remove ring gear if the ring gear is to be
replaced. The Trac-lok
y differential can be serviced
with the ring gear installed.
(3) Remove the pinion gear mate shaft lock screw
(Fig. 33).
(4) Remove pinion gear mate shaft with a drift and
hammer (Fig. 34).
(5) Install and lubricate Step Plate C-6960-3 (Fig.
35).
(6) Assemble Threaded Adapter C-6960-1 into top
side gear. Thread Forcing Screw C-6960-4 into
adapter until it becomes centered in adapter plate.
(7) Position
a
small
screw
driver
in
slot
of
Threaded Adapter Disc C-6960-3 (Fig. 36) to prevent
adapter from turning.
Fig. 31 Trac-lok
Y
Test -Typical
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 32 Differential Case Holding Fixture
1 - FIXTURE
2 - VISE
3 - DIFFERENTIAL
Fig. 33 Mate Shaft Lock Screw
1 - LOCK SCREW
2 - PINION GEAR MATE SHAFT
Fig. 34 Pinion Shaft
1 - PINION MATE SHAFT
2 - SIDE GEAR
3 - DRIFT
4 - PINION MATE GEAR
3 - 68
REAR AXLE - 8 1/4
AN
DIFFERENTIAL - TRAC-LOK (Continued)
(8) Install Forcing Screw C-6960-4 and tighten
screw to 122 N·m (90 ft. lbs.) maximum to compress
Belleville springs in clutch packs (Fig. 37).
(9) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 38).
Fig. 35 Step Plate
1 - LOWER SIDE GEAR
2 - DIFFERENTIAL CASE
3 - STEP PLATE
Fig. 36 Threaded Adapter Disc
1 - SOCKET
2 - SLOT IN ADAPTER
3 - SCREWDRIVER
4 - DISC
5 - FORCING SCREW
6 - THREADED ADAPTER DISC
Fig. 37 Compress Belleville Spring
1 - TORQUE WRENCH
2 - TOOL ASSEMBLED
3 - DIFFERENTIAL CASE
Fig. 38 Pinion Gear Thrust Washer
1 - THRUST WASHER
2 - FEELER GAUGE
AN
REAR AXLE - 8 1/4
3 - 69
DIFFERENTIAL - TRAC-LOK (Continued)
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