M220 TRAC-Lock/TRU-Lock Axle

DISASSEMBLY

Remove the ring gear. Refer to REMOVAL AND INSTALLATION .

Courtesy of CHRYSLER GROUP, LLC

1 - Ring Gear

2 - Ring Gear Bolts

3 - Differential Case

Clamp the (special tool #6963B, Fixture, Holding) in a vise and set the differential case on the fixture.

Courtesy of CHRYSLER GROUP, LLC

1 - Hammer

2 - Punch

3 - Roll Pin
Remove the pinion gear mate shaft roll pin from differential case using a suitable punch and hammer.

Courtesy of CHRYSLER GROUP, LLC

1 - Differential Case

2 - Pinion Mate Shaft
Rotate the differential case on the fixture and remove the pinion mate shaft.

Courtesy of CHRYSLER GROUP, LLC

1 - Disc

2 - Lower Side Gear

Lubricate and install the disc without the threaded hole from the (special tool #C-4487, Trac-Lok Axle Tool) into lower side gear.

Courtesy of CHRYSLER GROUP, LLC

1 - Upper Disc	3 - Forcing Screw
2 - Upper Side Gear	4 - Lower Disc

Lubricate and install the disc with threaded hole from the (special tool #C-4487, Trac-Lok Axle Tool) into upper side gear. Thread forcing screw from the (special tool #C-4487, Trac-Lok Axle Tool) into upper disc until it contacts the lower disc.
NOTE:
The slot in the threaded upper disc can be used to prevent it from turning using a screwdriver.

Courtesy of CHRYSLER GROUP, LLC

1 - Turning Bar

2 - Differential Case
Tighten the forcing screw to compress the Belleville springs in the clutch packs. Insert the turning bar from the (special tool #C-4487, Trac-Lok Axle Tool) into the pinion mate shaft hole in the differential case.

Courtesy of CHRYSLER GROUP, LLC

1 - Differential Side Gears

2 - Pinion Gears

Rotate the differential case with the turning bar until the pinion gears and washers can be removed.

NOTE:

Loosen the forcing screw in small increments to relieve the clutch pack tension if the differential case can not be rotated.

Courtesy of CHRYSLER GROUP, LLC

1 - Upper Clutch Pack

2 - Clutch Pack Retainers

3 - Upper Side Gear

Remove the forcing screw, step plate and threaded adapter.
Remove the upper clutch pack, clutch pack retainers and the upper side gear from the differential case.

Courtesy of CHRYSLER GROUP, LLC

1 - Differential Side Gears

2 - Differential Pinion Gears

Remove the lower clutch pack, clutch pack retainers and lower side gear from the differential case.

Courtesy of CHRYSLER GROUP, LLC

1 - Clutch Pack Retainers	3 - Clutch Pack
2 - Belleville Spring	4 - Side Gear

Remove the clutch pack retainers, clutch pack Belleville spring and the side gear. Keep the plates in order during removal.

ASSEMBLY

Courtesy of CHRYSLER GROUP, LLC

1 - Belleville Spring	4 - Side Gear
2 - Clutch Discs	5 - Retainer
3 - Retainer	6 - Plates

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.

Lubricate the components with gear lubricant.
Assemble the clutch discs, plates and Belleville spring into the packs and secure the disc packs with the retainers.
NOTE:
The Belleville spring is positioned with the convex side against the differential case.
Position the assembled clutch disc packs on the side gear hubs.

Courtesy of CHRYSLER GROUP, LLC

1 - Differential Side Gears

2 - Differential Pinion Gears

Install the lower clutch pack and side gear in the differential case, with the retaining clips seated in the case pocket.

Courtesy of CHRYSLER GROUP, LLC

1 - Upper Clutch Pack

2 - Clutch Pack Retainers

3 - Upper Side Gear

Install the upper clutch disc pack retaining clips and the side gear in the differential case pocket.

Courtesy of CHRYSLER GROUP, LLC

1 - Differential Side Gears

2 - Differential Pinion Gears
Lubricated and install the discs into the side gears from the (special tool #C-4487, Trac-Lok Axle Tool). Install forcing screw from the (special tool #C-4487, Trac-Lok Axle Tool) and the threaded screw to compress the Belleville springs in the clutch packs.
Install the pinion gears in the side gears opposite of each other.

Courtesy of CHRYSLER GROUP, LLC

1 - Turning Bar

2 - Differential Case
Rotate the differential case with the turning bar from the (special tool #C-4487, Trac-Lok Axle Tool) until the pinion gears align with the mate shaft holes in the differential case.
NOTE:
Loosen the forcing screw in small increments to relieve the clutch pack tension if the differential case can not be rotated.

Courtesy of CHRYSLER GROUP, LLC

1 - Pinion Gear Thrust Washers

2 - Differential Case
Install the pinion gear thrust washers between the gear and the differential case. Align the washers with the mate shaft hole in the case.

Courtesy of CHRYSLER GROUP, LLC

1 - Differential Side Gears

2 - Differential Pinion Gears
Remove the forcing screw upper disc from the side gear.
Remove the lower disc from the side gear.

Courtesy of CHRYSLER GROUP, LLC

1 - Roll Pin Hole

2 - Pinion Mate Shaft
Install the pinion mate shaft in the differential case.

Courtesy of CHRYSLER GROUP, LLC

1 - Roll Pin

2 - Differential Case

Install the pinion mate shaft roll pin.

Courtesy of CHRYSLER GROUP, LLC

1 - Ring Gear

2 - Ring Gear Bolts

3 - Differential Case

Install the ring gear with NEW ring gear bolts to the case assembly and tighten to the proper torque specification.
Lubricate all the differential components with gear lubricant.