[bruker]

How easy is it to rebuild a stock Trac-Lok differential? My `00 D44 has nearly 100,000 miles on it and I'm prety sure it's never been rebuilt.

[PhulesAu]

With what little it does, why waste the effort? Cost wise you might enjoy a more functional LS like a true trac. more bite and gear driven, not the clutch packs. No additive required.

[bruker]

My TJ is a daily driver and I only really need the trac-lok for snow and maybe occasionally a wet boat ramp. Where's a good place to get the clutch pack and does anyone know of a good write-up on how to do it?

[Wheelin98TJ]

From the FSM:

DIFFERENTIAL-TRAC-LOK

DISASSEMBLY

(1) Clamp side gear Holding Fixture 6965 in a vise
and position the differential case on the Holding Fixture
(Fig. 57).



(2) Remove ring gear if the ring gear is to be
replaced. The Trac-lok differential can be serviced
with the ring gear installed.
(3) Remove the pinion gear mate shaft lock screw
(Fig. 58).



(4) Remove pinion gear mate shaft with a drift and
hammer (Fig. 59).



(5) Install and lubricate Step Plate C-6960-3 (Fig.60).



(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-6960-1 (Fig. 61) to prevent
adapter from turning.



(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. 62).



(9) With a feeler gauge remove thrust washers
from behind the pinion gears (Fig. 63).



(10) Insert Turning Bar C-6960-2 into the pinion
mate shaft hole in the case (Fig. 64).



(11) Loosen the Forcing Screw in small increments
until the clutch pack tension is relieved and the differential
case can be turned using Turning Bar.
(12) Rotate differential case until the pinion gears
can be removed.
(13) Remove pinion gears from differential case.
(14) Remove Forcing Screw, Step Plate and
Threaded Adapter.
(15) Remove top side gear, clutch pack retainer
and clutch pack. Keep plates in correct order during
removal (Fig. 65).



(16) Remove differential case from the Holding Fixture.
Remove side gear, clutch pack retainer and clutch
pack. Keep plates in correct order during removal.


CLEANING

Clean all components in cleaning solvent and dry
components with compressed air.

INSPECTION

Inspect clutch pack plates for wear, scoring or damage.
Replace both clutch packs if any one component
in either pack is damaged. Inspect side and pinion
gears for cracks chips or damage and replace as necessary.
Inspect differential case and pinion shaft and
replace if worn or damaged.

ASSEMBLY

NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.

(1) Lubricate components with gear lubricant.
(2) Assemble clutch discs into packs and secure
disc packs with retaining clips (Fig. 66).
NOTE: Dished plate is position with the convex side
against the side gear.



(3) Position assembled clutch disc packs on the
side gear hubs.
(4) Install clutch pack and side gear in the ring
gear side of the differential case (Fig. 67).Verify
clutch pack retaining clips are in position and
seated in the case pockets.

See pic in post below.

(5) Position the differential case on the Holding
Fixture 6965.
(6) Install lubricated Step Plate C-6960-3 in lower
side gear (Fig. 68).

See pic in post below.

(7) Install the upper side gear and clutch disc pack
(Fig. 68).
(8) Hold assembly in position. Insert Threaded
Adapter C-6960-1 into top side gear.
(9) Install Forcing Screw C-6960-4 and tighten
screw to slightly compress clutch disc.
(10) Place pinion gears in position in side gears
and verify that the pinion mate shaft hole is aligned.
(11) Rotate case with Turning Bar C-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.
(13) 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.
(14) Remove Forcing Screw, Step Plate and
Threaded Adapter.
(15) Install pinion gear mate shaft and align holes
in shaft and case.
(16) Install pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
(17) Lubricate all differential components with
hypoid gear lubricant.

[Wheelin98TJ]

[jzmtl]

So you need to reset the gears to replace the clutch pack? Damn that sucks.

[Wheelin98TJ]

Originally Posted by jzmtl

So you need to reset the gears to replace the clutch pack? Damn that sucks.

No need to reset the gears.

The pinion gear will remain in the axle housing so nothing gets disturbed there.

With the carrier shims and bearing caps, just note their orientaton and position and reinstall everything the same way it comes out.

[bruker]

Wow! Thanks Wheelin98TJ!

[gs2offroad]

There is a tech article on Randy's Ring-n-pinion site that reveals some tips to assemble the Trac-Lok carrier
Trac-Loc Assembly Made Easy

[jayvando707]

Originally Posted by Wheelin98TJ

No need to reset the gears.

The pinion gear will remain in the axle housing so nothing gets disturbed there.

With the carrier shims and bearing caps, just note their orientaton and position and reinstall everything the same way it comes out.

Let me get this straight.... Im a newbie so be patient!

I can remove carrier w/ the ring gear (i circled it in the image hahahaha) and it WONT mess with the backlash?

[Wajoe]

What is the expected service life on a trac-loc before it needs this anyway? I've seen one estimate of 50k miles but dunno if that was just one of the nay-sayers.

[Wheelin98TJ]

Originally Posted by jayvando707

Let me get this straight.... Im a newbie so be patient!

I can remove carrier w/ the ring gear (i circled it in the image hahahaha) and it WONT mess with the backlash?

Correct.

You are not changing or moving any shims.

The shims for the carrier set backlash. If you put them back in where they originally were, you end up with the same backlash.

Originally Posted by Wajoe

What is the expected service life on a trac-loc before it needs this anyway? I've seen one estimate of 50k miles but dunno if that was just one of the nay-sayers.

50k is a little conservative, but possible for someone who uses it a lot.

It could last 100k with an easy driver.

[Wajoe]

Originally Posted by Wheelin98TJ

50k is a little conservative, but possible for someone who uses it a lot.

It could last 100k with an easy driver.

Cool, mine is at 63k and has been city stuck for at least half of it's life before I got it. Certainly proved itself on the one trip I've been able to get at some dirt since picking up the jeep(not very extreme stuff, but some pretty loose steep hills where I could tell it helped).

Thanks for the how-to above Printed for future reference.

[txhotrod]

I know this is an old thread but I was wondering if anybody knows of where to get the tool that compresses the clutch packs? I've done a seach on the net for those tool numbers but no luck?

JOE