DANA TRAC-LOK 60 Service Manual Download Page 4

MODEL 60 TRAC-LOK 

5.  Repeat  Steps 2. 3. and 

·�. 

making sure to replace 

the  cover gasket,  if required, in Step 2. 

6.  It is  possible that  slight  chatter,  requiring  addi· 

tiona! vehicle operation may remain after S

t

P

p 5. 

If chatter  still  persists  after one hundred (100) 

miles  of  vehicle  operation,  or  remains  scwr� 

after Step 

above, disassemby and repair "ill be 

ne

cessar

y. 

UNIT INOPERATIVE 

Proper performance and capabilities 

of 

Limited Slip 

Differentials  are  often  misunderstood. If  in  doubt, 

read "Operation"  above. 

No 

precise  methods of measuring Limited Slip Dif· 

ferential  performance  are  generally  available  in 

th

field.  A 

functioning  unit can be determined by these 

relatively simple  vehicle  operational tests. 

I. 

Place one 

wheel 

on good dry pavement, and the 

other  on  ice, mud,  snow,  etc. 

2. 

Gradually  open the throttle to obtain maximum 

traction  prior  to "break-a-away". The ability to 

move  the  vehicle  effectively  will  demonstrate 
proper performance. 

3. 

If extremely  slick  surfaces, such as  ice  is used, 

some  question may  exist as  to proper !M'rform· 
ance at Step 2. In these extreme cases. a proper· 

ly 

performing Umited Slip Differential will pro· 

vide greater "pulling power" by lightly applying 
the  parking  brake. 

It should be realized that even 

with 

a properly func· 

tioning limited slip differential, it is possible to have a 

vehicle hopelessly stuck.  This can occur when vehicle 
resistance exceeds the maximum possible tractive ef· 

fort  which can be obtained. 

differential  can do no 

more than provide torque to slip both drivi

ng 

wheels. 

If this torque is not sufficient to move the vehicle. not 

even  a  completely locked differential can do  more. 

DISASSEMBLY 

REMOVAL, INSPECTION  AND 

REPAIR  OF TRAC-LOK 

On Dana Spicer  axles.  it  is  recommended that 

the 

complete assembly 

be 

removed from 

the 

vehicle when 

it becomes necessary to remove the Trac-Lok from t

he 

housing. 

Remove  wheels, brake  drums, brake hacking  plate 

screw-s  and axle shafts. Brake hacking  plates can nor· 
mally  be  wired  to  frame 

without  loosening 

the 

hydraulic brake line connection at the wheel cylinder 

if desired. Lse cauuon to avoid  damage to brake hne. 

Remove axle assembly and place in rack or stand to 

serve  as  a holding  device. 

Remove  cover platr 

screws 

and cover plate. If cover 

gasket is used, discard gasket and replace with nrwone 
at time of  assembly. 

FIGURE #2 

101$-2 

Remove  differential  bearing  caps. 

Note  letters 

stamped on the bearing caps and the cover face of the 

housing.  Letters  are  tO correspond  in 

horizontal 

and 

vertical positions.  This  is  very  important  at time 

of 

assembly. 

FIGURE  #3 

....... 

Mount spreader to  housing. Locate a dial  indicator 

with  a magnetic base  on cover face 

as 

shown. Locate 

tip of indicator  on housing  as shown. 

Set dial indicator at zero 

("0"). 

Turn forcing screw 

of  spreader  until  indicator records .015" (.38 mm). 

CAUTION 

DO NOT  SPREAD 

CARRIER 

I N  

EXCESS OF 

.015"  (.38 mm). 

Remove 

I

ndi

ca

t

or 

Tools: 

D-167  Spreader  D-128 Indicator Set 

Summary of Contents for TRAC-LOK 60

Page 1: ...MODEL 60 TRAC LOKTM LIMITED SLIP DIFFERENTIAL SPICER MODEL 60 TRAC LOK LIMITED SLIP DIFFERENTIAL SPICER AXLE DIVISION DANA CORPORATION P ORT WAYNE INDIANA ...

Page 2: ...scribed in this service manual are effective methods for performing service operations Some of these service operations require the use of tools specially designed for the purpose The special tool should be used when and as recommended It is impossible to know evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of e...

Page 3: ... Slip Differentials impose additional re Jirements on lubricants which cannot be covered y the above specifications Some otherwise good bricants produce chatter or bumping in turn g corners with Limited Slip Differentials Many lhicle manufacturers find it necessary to specify a 3 special lubricant or lubricant additive for use with Limited Slip Differentials Check the vehicle manufacturer s lubric...

Page 4: ...ccur when vehicle resistance exceeds the maximum possible tractive ef fort which can be obtained A differential can do no more than provide torque to slipboth driving wheels If this torque is not sufficient to move thevehicle not even a completely locked differential can do more DISASSEMBLY REMOVAL INSPECTION AND REPAIR OF TRAC LOK On Dana Spicer axles it is recommended that the complete assembly ...

Page 5: ...do not locate on axle splines or any machined surfaces NOTE SOME SEMI FLOAT AXLES REQUIRE SPACER BLOCKS BETWEEN THE AXLE SHAFTS FOR BEARING END PLAY ADJUST MENT THE SPACER BLOCK IS NOT USED 5 ON FULLFLOAT OR SEMI FLOAT AXLES WITH NON ADJUSTABLE WHEEL BEAR INGS FIGURE 6 101 Place a few shop towels over vise to prevent any damage during disassembly of ring gear Assemble the differential on the axle ...

Page 6: ...mmended that when referring to the Trac Lok obtain the complete part number and build date To do this it will be necessary to wipe offthe lubricant from the case FIGURE 9 101S t Remove the cross pinand spacer block if so equip 6 ped l se a hammer and punch as shown to remove the cross pin from the case NOTE AXLE SHAITS WHICH REQUIRE END PLAY ADJUSTMENT HAVE A SPACER BLOCK l N THE DIFFERENTIAL CASE...

Page 7: ...ingscrew until it becomes slightlytight This will collapse the Belleville plates and allow a loose condition between the side gears and pinion mate gears Remove both pinion mate spherical washers Use a shim stock of 030 76 mm thickness or an equiva lent tool to push out the spherical washers Relieve the tension in the Belleville plates by loosening the forcing screw FIGURE 14 1015 14 Insert large ...

Page 8: ... and pinion mategears The gearteeth ofthese parts should be checked for extremewear and possible cracks The external teeth of the side gear which retain the concentric groove discs should also be checked for wear or cracks If replacement of onegear is required due to wear 8 etc then both side gears pinion mate gears and washers are to be replaced Cross Pin If excessive wear is evident the cross pi...

Page 9: ...pecified lubricant 9 SlOE GEAR OISHEO SPACER FIGURE 20 101 20 Assemble the retainer clips to theears of theplate Make sure bothclips are completely assembled or seat ed onto the ears of the plates With thediffere ntial case positioned as shown as semble the clutch pack and side gear into the case Make sure the clutch pack stays assembled to the side gear splines and that the retainer clips are com...

Page 10: ...ottom plate This will hold both clutch packs in position With tools assembled into the case position case onto the axle shaft by aligning the splines of the side gear with those of the shaft FIGURE 24 101S 24 Loosenforcing screw slightly Assemble both pinion mate gears as shown Hold gears in position by hand While holding gears inplace insert turning bar into case Pull on bar to rotate case allowi...

Page 11: ...FIGURE 27 101S J7 Using a scale as shown wrap a pieceoftape around the punch approximalely I 3 4inches 44 5mm from the end of he punch This indicates the necessary deplh required for assembly of he lock pin 11 FIGURE 28 101S 21 Assemble lock pin Hi on punch unlil he ape on rhe punch is lined up wilh he case Remove case from axle shaf1 Assemble ring gear10 e Uneup he ring gear screw holes wilh hose...

Page 12: ... gear are meshedwith those of pinion Use a ra wh id ehammer to seat differenti al assembly in t o cross bore of housing Care shouldbe taken t o a vo i d nickin g the teeth of the ri nggear and pinion dur ing assembly 12 Remove spreader FIGURE 32 101 Installbearing caps Make sure the let t ers stamped on t he caps cor re spond with those stamped on the hous ing in horizontal and vertical positions ...

Page 13: ...54 N m 13 NOTE IF SPICER AXLE TORQUE SCREWSTO 30 40 LBS IT 41 45 N m NOTE ON ALL FRONT AXLES THECOVERPLATE IS OF A DIFFERENT DESIGN AND R QUIRES THE USE OF A CASKET DO NOT USE A SILICONE RUBBER SEALER MAT ERIAL Assemble axle in vehicle Fill axle with the s pe ci fied lubricant Refer to v ehicle manufacturer s lubri cant recommendations Assemble brake backing plates etc and axleshaf ts into housing...

Page 14: ...own toprotect the bear ingfrom becoming damaged during a ssem bl y of t op bea rin g Tools C4025 Installer C4171 Handle DD 914 42 Button Prelubricate dif ferentia l bearing cones with the specifi ed lub r i cant Assemble case into housin g Follow the steps as illustrated in Figures 30 thru 32 14 FIGURE 38 1015 SII Check ringgearand pinion backlashinthree equally spaced points with dial indicator a...

Page 15: ...e changes from time to time without notice or obligation in specifications descriptions and illustrations and to discontinue models or revise designs Questions regarding this manual should be directed to Spicer Axle Division Dana Corporation P O Box 1209 Fort Wayne Indiana 46801 Attention Engineering Technical Service Dept 2 84 500 ...

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