How to Stack Clutches for a Clutch Style Positraction | Differential Tech Tips

Learn how to properly stack the clutch pack prior to rebuilding Yukon Dura Grip or similar clutch style positraction device. Stacking order and friction modifier application are covered.
Music by Jason Shaw @ audionautix.com

[@maga_q_anon8384]

I have a 1999 Dodge 3500 Dana 80 35 Spline. My differential has a concave spacer. 1 thick single side clutch, then a smooth plate, then double sided clutch, then smooth plate, then a double sided clutch, smooth plate. If I put all of the plates and clutches in, the yoke with the spider gears do not sit flush with the differential housing. I have to take one smooth plate out on each side in order for the spider gear yoke to sit flush. When I do that I have play in the axle gear. If I do not take them out the gears are hard to move. I'm assuming the plates are too thick. I do not want to put some of the old plates in due to them being warn out. Should I take a digital caliper to the old disc clutches and plates and see what the thickness is compared to the new ones?

[@66and72nova1]

Dodge Dana 80 powerloc vs Trac lock. It should be know but it's isn't talked about. A Dana powerloc may be a track lock. Although, the exterior case is the same design as a 60 and 70 powerloc, the cross shaft does have ramps however, the cross shaft is one piece. Therefore, it's a track lock. What's more confusing is the the internials do not interchange with a track lock except for the clutches. Also, the 80 powerloc/ track lock shares the same pinion gears. You can replace the one piece cross shaft (power lock design with a real two piece cross shaft so the cross shafts can ramp. The 80 hats and side gears are different than the 60/70 powerloc. The 80 hats are thinner in width than the 60/70 and are not as beveled (deep). Also the 80 side gears are not has thick gear width. Also, the 80 clutch spline depth is much longer... You must use original factory clutches (lined/ round rings). Using 60/70 clutches will not work however, the 80 real track lock clutches interchange. Track lock case is different, flat cross pin one piece, no hats and uses pinion thrust washers.... Again nothing interchangeable into the Dana 60/70 powerloc except for the 80 powerloc case that was called a track lock by it's own design and unique to itself. Four wheels,. Take all the internials from one of these 80 units and put it into your 60/70 powerloc lock and replace the cross shaft with a two piece. Factory is five friction sides on the clutches or you can move the disc and plates to seven or nine friction sides and be almost a spool. This can also be done to the 80 track lock however, you won't have the ramping design.