Clutch Pack Preload

1. Assemble the clutch pack on the side gear (no shim required at this point). However, all plates must be pre-lubricated with Additive Friction Modifier C8AZ-19B546-A (EST-M2C118-A) or equivalent hypoid gear lubricant.
   
   
   
   

2. Assemble Traction-Lok Clutch Gauge T80P-4946-A on side gear clutch pack.
   
   
   
   

3. Using a feeler gauge tool, select the thickest feeler blade that will enter between the tool and the clutch pack.
   
   
   
   

   NOTE: Do not mix the clutches or shims.

4. Note the thickness; this will be the shim required for that clutch pack.

5. Repeat Steps 1 through 4 for the opposite clutch pack.

Assembly

1. Lubricate all parts with rear axle lubricant prior to assembly.

2. Mount the differential case in a soft-jaw vise and place the clutch packs and side gears in their proper cavities in the differential case.

3. Place the pinion gears and thrust washers on the side gears.
   
   
   
   

4. Install Gear Rotator Traction-Lok T80P-4205-A in the differential case.

5. Rotate the pinion gears until the bores in the gears are aligned with the pinion shaft holes in the differential case. Remove the tool from the differential case.

   NOTE: Inspect the spring for damage.

6. With a soft-faced hammer, install the S-shaped preload spring in the differential case. If necessary, complete the installation of S-shaped preload spring with a brass drift.
   
   
   
   

   NOTE: Do not tighten the lock bolt at this point. The pinion shaft and lock bolt will be removed to install the axle shafts. Once the axle shafts and retaining washers are installed, then the differential pinion shaft and lock bolt may be installed and tightened to specification.

7. Install the pinion shaft and lock bolt.

8. Prior to installation of the locking differential into a vehicle, a bench torque check must be made. With Traction-Lok Torque Tool T59L-4204-A, check the torque required to rotate one side gear while the other is held stationary.
   
   
   
   

   If original clutch plates are used, the initial breakaway torque should be at least 27 Nm (20 lb-ft). The rotating torque required to keep the side gear turning with new clutch plates may fluctuate with initial breakaway torque at least 27 Nm (20 lb-ft).
   
   
   
   

9. Clean the tapped holes in the ring gear with a suitable solvent. If the new bolts to be used show a green coating over approximately 12.7mm (1/2 inch) of the threaded area, use as is. If not coated, apply a small amount of Stud and Bearing Mount E0AZ-19554-BA (WSK-M2G349-A1) or equivalent. Tighten to 95-115 Nm (70-85 lb-ft).

10. For installation of differential case and ring gear, refer to Section 05-02B.