1988 JEEP CHEROKEE clutch

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DIF FE R EN TIA L - D AN A T R AC -L O K & P O W ER -L O K

1988 J e ep C hero ke e
1988 Positive Traction Differentials - Dana Power-Lok &
Trac-Lok
Jeep
DESCRIPTION
The limited slip differential uses 2 sets of multiple disc
clutches to control differential action. Dana produces 2 types of
positive traction differentials. The Power-Lok 4-pinion differential
is a split-case type. The Trac-Loc 2-pinion differential is a single-
case type.
OPERATION
When one or both wheels are on a low-traction surface such as
snow, ice or mud, the friction between the clutch plates will transfer
a portion of the usable torque to the wheel with the most traction.
The wheel on ice or snow will have a tendency to operate with the
opposite wheel in a combined driving effort.
AXLE RATIO & IDENTIFICATION
To determine axle ratio, see DRIVE AXLE RATIO IDENTIFICATION
in this section.
LUBRICATION
NOTE: Always use special positive traction differential lubricant
as specified by manufacturer.
DIAGNOSIS & TESTING
DANA 2-PINION TRAC-LOK
1) Drive vehicle to thoroughly warm up lubricant in rear
axle. Place a piece of slick paper over a smooth formica board. Ensure
formica board is on flat and level floor.
Fig. 1: Exploded View of Jeep Single-Case Dana Trac-Lok Differential

Plate (J 23781-7) in bottom side gear. Install grease in centering
hole of step plate. Position Rotating Tool (J 23781-3) on step plate
tool. Coat threads of Forcing Screw (J 8646-2) with oil.
2) Insert forcing Screw (J 8646-2) through case and thread
into rotating tool. Thread screw through tool until it contacts
centering hole in step plate. Tighten forcing screw to relieve clutch
pack tension from pinions. Remove pinion thrust washers.
3) Tighten forcing screw until all clutch pack tension is
relieved from pinions. Slide rotating tool pawl so it engages with
side gear teeth. Rotate side gears with rotating tool until pinions
can be removed through case opening.
4) Remove forcing screw, rotating tool, upper side gear and
clutch pack. Remove differential case from axle shaft. Remove
remaining side gear, clutch pack and step plate tool. Remove retainer
clips from clutch packs. Mark clutch packs for reassembly reference.
Using a press, remove differential bearings.
Cleaning & Inspection
Clean all parts and dry with compressed air. If any clutch
plates or discs require replacement, all plates and discs should be
replaced. Replace any worn or damaged components.
NOTE: For adjustment procedures, see DANA SEMI-FLOATING or
FULL FLOATING AXLE articles in this section
Reassembly
1) Lightly lubricate clutch pack discs with axle lubricant.
Assemble clutch pack discs and install retaining clips on ears of
discs. See Fig. 3. Install assembled clutch packs on side gears.
Fig. 3: Typical Clutch Pack Assembly
2) Mount differential case on axle shaft. Install first
clutch pack and side gear in bottom bore of case. Ensure retaining
clips remain seated in case pockets. Install Step Plate (J 8646-2) in

clutch pack just installed.
3) Install remaining side gear and clutch pack in case. Hold
assembly in position and install rotating tool and forcing screw.
Tighten forcing screw and compress clutch packs. Install pinions.
Rotate side gear with tool pawl until each pinion is aligned with
pinion shaft bore.
4) Install pinion thrust washers and pinion shaft. Install
pinion thrust washers and pinion shaft. Install snap rings on pinion
shaft. Remove differential from axle shaft. Remove shaft from vise.
Using Remover (J 22912-01), remove differential bearings. Install end
play shims on each side of case. Reinstall differential bearings.
5) Position ring gear on differential case. Install NEW ring
gear bolts and tighten to 52 ft. lbs. (70 N.m).
DANA 4-PINION POWER-LOK
NOTE: Differential bearings do not need to be removed to overhaul.
Disassembly
1) Mark case halves, pinion mate shafts and ramps for
reassembly reference. Clamp differential assembly in soft-jawed vise
and loosen case half bolts ( DO NOT remove bolts). Position
differential assembly on bench with ring half of case down. Remove
case attaching bolts. Remove cover half of case.
2) Remove pinion mate gear, side gear ring and clutch pack.
Keep parts together for reassembly reference. Remove parts from drive
gear half of case.
Cleaning & Inspection
Clean all parts and dry with compressed air. If any clutch
plates or discs require replacement, it is recommended that all plates
and discs be replaced. Replace any part that is worn or damaged.
Reassembly
NOTE: For adjustment procedures, see DANA SEMI-FLOATING or
FULL FLOATING AXLE articles in this section.
1) Position side gear ring from drive gear half of case on a
pinion flange. Coat clutch plates with Hypoid Gear Lubricant (C6A-Z-
19580-E). Reassemble parts in correct order. See Fig. 1. Install ring
gear half of case over clutch pack and side gear ring. Ensure clutch
plate lugs enter slots in case and case bottoms on clutch pack.
2) Hold assembly together and turn case half upside down.
Install gear in side gear ring. Install mate shaft and pinions on side
gear ring. Align mate shaft and case markings. Install cover half mate
shaft and pinions. Align markings.
3) Install side gear on pinions. Position side gear ring on
side gear and pinions. Assemble clutch pack on side gear. See Fig. 4.
Align clutch plate lugs and install all parts in case. Position cover
half of case over assembly. Align case marks made during disassembly.
4) Lubricate bolt threads with axle lube and install case
bolts. Using both axle shafts, align splines of side gear and side
gear ring. Tighten case bolts to 65-70 ft. lbs. (89-94 N.m).
5) Remove axle shafts. If properly assembled, each pinion
mate cross shaft should be tight on its ramp. If clearance is present,
it should not exceed .010" (.254 mm).

Fig. 4: Power-Lok Differential Clutch Pack Assembly
Courtesy of Ford Motor Co.

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* D RIV ETR AIN S YSTE M S U NIF O RM IN SPEC TIO N G UID ELIN ES *
1988 Jeep Cherokee
GENERAL INFORMATION
Drivetrain/Transmission Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Drive/Power Train Assemblies
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
TRANSFER CASE ASSEMBLIES
Drive/Power Train Components
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AXLES
BEARINGS AND RACES
BELL CRANKS
BELL HOUSINGS
BUSHINGS (EXTERNAL)
CABLES (SPEEDOMETER)
CABLES (TV, DETENT AND SHIFT)
CARRIER BEARINGS
CLUTCH CABLES AND CABLE HOUSINGS
CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH FORKS
CLUTCH LINKAGES (MECHANICAL)
CLUTCH MASTER CYLINDERS
CLUTCH PEDALS
CLUTCH PIVOTS
CLUTCH PRESSURE PLATES
CLUTCH RELEASE BEARINGS
CLUTCH SLAVE CYLINDERS (CONCENTRIC)
CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
COMPANION FLANGES
CONNECTORS
COOLER BYPASS VALVES
COOLER LINES
COOLERS
CV JOINTS
DIP STICK TUBES
DIP STICKS (FLUID LEVEL INDICATORS)
DOWEL PINS, GUIDES AND PILOT HOLES
DRIVE SHAFT FLANGES
DRIVE SHAFTS AND HALF SHAFTS
DUST BOOTS
ENGINE MOUNTS
EXCITER RINGS
FILLER TUBES
FILTERS AND SCREENS

Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Bracket cracked, affecting
performance ............ A .. Require repair or replacement.
Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Broken .................. A ............ Require replacement.
Cracked ................. A .. Require repair or replacement.
Disconnected ............ A .. Require repair or replacement.
Frayed .................. A ............ Require replacement.
Kinked .................. A .. Require repair or replacement.
Melted .................. A ........... (1) Require repair or
replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Out of adjustment ....... B ........... ( 2) Require repair or
replacement.
Routed incorrectly ...... 2 ................. Suggest repair.
Seized .................. A .. Require repair or replacement.
Self-adjuster
inoperative ............ A .. Require repair or replacement
of self-adjuster.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Cable replacement is required if it cannot be adjusted
within specifications.









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CARRIER BEARINGS
See INTERMEDIATE SHAFT SUPPORT BEARINGS .
CLUTCH CABLES AND CABLE HOUSINGS
CLUTCH CABLE AND CABLE HOUSING INSPECTION








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Condition Code Procedure
Broken .................. A ............ Require replacement.
Cable bent .............. A ............ Require replacement.
Cable binding ........... A .. Require repair or replacement.
Cable mounting loose .... B .. Require repair or replacement.
Cable out of adjustment . B .. Require repair or replacement.
Frayed .................. B ............ Require replacement.
Housing heat-damaged .... 1 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Seized .................. A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION








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Condition Code Procedure
Backing plate cracked ... A ............ Require replacement.
Broken .................. A ............ Require replacement.
Contaminated with oil ... A ............ Require replacement.
Damper cushion broken ... A ............ Require replacement.
Damper cushion
collapsed .............. A ............ Require replacement.
Damper spring collapsed . A ............ Require replacement.
Damper spring missing .. C ........ ( 1) Require replacement.
Friction material cracked
through ................ B ............ Require replacement.
Friction material flaking
or chunking ............ B ............ Require replacement.
Friction material surface
cracking ............... B ......... No service suggested or
required.
Grooved ................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Ridged .................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Splines worn, affecting
performance ............ A ............ Require replacement.
Warped .................. A ............ Require replacement.
Wear exceeds
specifications (where
applicable) ............ B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.
( 1) - Not all clutch discs have springs in all spring
chambers on the disc.









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CLUTCH FORKS
CLUTCH FORK INSPECTION








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Condition Code Procedure
Bent .................... B ............ Require replacement.
Broken .................. A .. Require repair or replacement.
Cracked ................. B .. Require repair or replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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CLUTCH LINKAGES (MECHANICAL)
See LINKAGES (EXTERNAL) .
CLUTCH MASTER CYLINDERS
CLUTCH MASTER CYLINDER INSPECTION








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Condition Code Procedure
Cover gasket distorted .. A .... Require replacement of cover
gasket.
Cover gasket gummy ...... A .... Require replacement of cover
gasket.
Cylinder leaking fluid
from rear of bore ...... A .. Require repair or replacement.
Cylinder leaking fluid
internally ............. A ............ Require replacement.
Dust boot missing ....... C ..... Require replacement of dust
boot.
Dust boot punctured ..... A ..... Require replacement of dust
boot.
Dust boot torn .......... A ..... Require replacement of dust
boot.
Fluid level incorrect ... B . Require fluid level adjustment.
Housing damaged, affecting
performance ............ A .. Require repair or replacement.
Master cylinder has
residue in reservoir
(make parallel w/brakes
when they are done) .... 2 .......... ( 1) Further inspection
required.
Threads damaged ......... A ...... Require repair replacement
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - DO NOT replace master cylinder unless it exhibits
conditions listed for replacement. You may suggest fluid
change according to OEM service intervals.









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CLUTCH PEDALS
CLUTCH PEDAL INSPECTION








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Condition Code Procedure
Bent, affecting
performance ............ A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Pedal pad missing ....... C .......... Require replacement of
pedal pad.
Pivot bushings worn,
affecting performance .. A .... Require replacement of pivot
bushings.









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CLUTCH PIVOTS
CLUTCH PIVOT INSPECTION








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