Initial Inspection and Diagnostic Overview

1. Clean all parts in suitable solvent. Dry all parts except bearings with compressed air or shop towels. Allow bearings to air dry or use shop towels. Do not use compressed air to dry bearings as damage may result.
2. Inspect differential bearings and cups for wear, pitting, galling, flat spots or cracks. Any bearing or cup showing any signs of wear or damage must be replaced. Bearings and respective cups must be replaced as an assembly only. Do not attempt to interchange bearings and cups as bearing life will be affected.
3. Inspect non-machined differential case surfaces for nicks and burrs which can be removed with an oil stone or fine tooth file. Inspect pinion shaft bore to ensure it is not elongated or worn. If damage is evident, differential case must be replaced. Inspect machined differential surfaces and counterbores. They must be smooth and free of nicks, gouges, cracks and other visible damage. If damage is evident, differential case must be replaced.
4. Inspect pinion shaft for excessive wear, scoring or galling. Ensure shaft is smooth and concentric. If any wear or damage is evident, replace the shaft. Inspect pinion shaft lockpin for damage and to ensure it has a snug fit in the differential case. Replace lockpin or case as necessary.
5. Inspect pinion and ring gears for worn or chipped teeth, cracks, damaged bearing journals or attaching bolt threads. If any of the above are evident, replace ring gear and pinion as a matched set.
6. Inspect pinion and side gears. Gears must exhibit a uniform contact pattern without any signs of cracks, wear, scoring or galling. If any of the above are evident, replace all the gears. Inspect thrust washers for wear and replace as necessary.
7. Inspect pinion and ring gears for worn or chipped teeth, cracks, damaged bearing journals or attaching bolt threads. If any of the above are evident, replace ring gear and pinion as a matched set.
8. Inspect axle shaft C-locks for signs of cracks or wear and replace as necessary.

The cleaning and inspection of a Traction-Lok limited slip differential is the same as for conventional differentials except that cleaning solvent should not be allowed to contact the clutch plates. The clutch plates should be wiped clean only. In addition, the following steps should be performed which only apply to the Traction-Lok differential:

1. Visually inspect clutch packs, side gears, pinion gears and pinion shaft for damage or wear and replace as necessary.

Shim Thickness Measuring:

2. Place each clutch pack without shims into tool T80P-4946-A, or equivalent.

Shim Thickness Measurement:

3. Torque nut to 60 in lb. Using feeler gauge, determine thickness of new shims by inserting thickest blade possible between clutch pack and tool, then note size for use during assembly.