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PG/Dana PowerLok
Right Side
PG/D44 PowerLok
Left Side
Here is our guinea pig! A PowerLok from Precision Gear. I bought this thing used from Shaggy on ColoradoK5. Shaggy sold it cause he ate a ring and pinion and the D44 no longer tasted good to him. He went D60. When I got it I opened it up and found the clutch pack had eaten some metal so I ordered a clutch pack from Florida4x4 Forum member Toy Maker. (BTW: Shaggy sent me the cash for the new clutches since he advertised the PL in perfect condition. Way to go Shaggy!! Way Cool!!) So anyway, I fully intended to install the PL in my 72 Jimmy but little did I know I would find a deal on a D60. Hey who's complaining? Not me!

Before I shipped it to the new owner I installed the new clutches. The unit is really simple but I called Precision Gear "just in case". Tech support was really helpful and took time to explain the function and assembly of the unit. The clutch pack had a couple of concave (or convex if you look from the other side) plates that can modify the action making it more or less agressive. Read on!

Click on the images for a larger pic...
Alignment markings
Alignment markings
I don't know for sure if the case can be assembled backwards, 90* out, whatever, so for good measure I put a couple of alignment marks on the case.

NOTE: Anytime you are dealing with machined case halves it's a good idea to make some form of mark to ensure you put it back together as it was manufactured.


Spider Crossshafts
Spider Crossshaft 1
Spider Crossshaft
Spider Crossshaft 2
D44 PowerLok Clutches
Spider Crossshaft 3
The next three pics show the meat of the PowerLok. Most differentials spider gears are installed on non-moving shafts. In the PL the crossshafts are pressed against the housing by the tension of the clutch plates. Under power, the force on the spiders cause the crossshafts to begin to seperate. This action puts more force on the clutch packs in effect creating more spring tension and forcing more power to the ground.

Top pic shows the two cross shafts nice and comfy in their home.

Middle pic shows one cross shaft removed and the final pic shows the spider gear that mates with the axle shaft. This spider has splines that engage in a cone shaped spacer which rides against the clutch pack.











Parts is Parts
Parts is Parts
Here is the unit all apart, spread out and looking good. Interesting thing here is that the clutches nearly fell off in my hands. I found out later that the new ones have an interference fit and require some pressure to install.



New Clutches
New Clutches
The new clutches. The package includes two convex clutches with tabs that engage in the PL housing, four flat plates that engage on the outer spiders and four center plates.




Left Case Half
Left Case Half
Assembly starts! Be sure to have some friction modifier handy for the clutch plates. Lube up the entire clutch assembly with friction modifier and save the rest to throw in the axle once it is assembled.



Right Case Half
Right Case Half
The first plate to go in is the convex one. Here is where you can mofify the action of the PL. Picture the clutch assembled in the differential case. looking from either side the very first plate is the convex plate. By turning the plate so it is concave you increse the tension on the clutch pack - in other words you get a more agressive limited slip.


Clutch Block
Clutch Block
Here is the backside of the side spider gear. You see the splines on the spider engaged with the cone shaped clutch block. It may seem like you should place the clutch plates in the differential housing and then insert the splined spider/cone assy. Wrong! The clutch plates that engage on the spider splines have an interference fit. See the next pic!


Clutch Pack
Clutch Pack
Assembly of the clutch pack goes like this. First plate has dog ears, second plate engages on the splines (use a socket and rubber mallet to seat the plate), third another plate with dog ears, and so on until you reach the final convex plate.



Assembled Pack
Assembled Pack
Here is the final assembly before being placed in the case half. Be careful when placing the clutch pack in the housing. The clutch block has very close tolerances and will get wedged easily if not installed properly.



PowerLok Assembly
Assembly
Once the clutches are in the case halfs, replace the spider crossshafts and slide the cases together. Pay attention to the alignment marks! The case bolts have substantial lockwashers but even so a little locktite helps guarantee the case will not seperate out on the trail. Tighten the bolts criss-crossing as you go to make sure the cases are brought together evenly. Once they are snug, torque them to 35 ft/lbs.

Freshened PowerLok
Freshened Powerlok
And here it is... the most fabulous object in the world... a like new PowerLok ready for installation! (say? were you expecting a new kitchenette?)





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