QK4607 1999-2002 Dodge Dana 80 Trac-Lok Clutch Replacement Kit

QK4607 Early 1999-2002 Dodge Dana 80 Trac-Lok™ Clutch Replacement Kit for early 1999-2002 Dodge Ram 2500, Ram 3500 with factory Limited Slip Dana 80 Rear Axles. Is your 1999-2002 Dodge rear diff chattering or slipping? Chances are the original clutch packs are worn out. Rebuild your factory limited-slip differential with genuine Dana-Spicer replacement parts. Each kit includes complete Clutch Packs, 8oz. of Limited Slip Additive, Axle Shaft Flange Gaskets, Threadlocker, & RTV sealant. USA Made.

ALSO SEE: QU40430 Trac-Lok™ Gear and Clutch Kit

Need More Info? Use the handy Links below to access over 40 years of Dan's product and vehicle specific Tech Notes to easily get the information you need for your vehicle's repair, maintenance, or upgrade project!

Dan the Gear Man® Tech Notes:
Kit Components
Powr-Lok™ and Trac-Lok™
Design Change
Before Assembly
Matching Parts
Tech Help
Pinion Depth
Applications

Tech Note 1: Kit Components
QK4607 Component Parts:
QU40276 Powr-Lok™ Limited Slip Clutch Set
2 QU40218 4 ounce Bottles Limited Slip Lubricant
2 QU40078 Axle Shaft Flange Gaskets
2 S9978 Threadlocker
S82194 RTV Sealant

Tech Note 2: Powr-Lok™ and Trac-Lok™
During the 1994 to 2002 model years, Dodge Ram 2500 and 3500 trucks using Dana-Spicer rear axles were available with an optional clutch-type Limited Slip differential. For the Dana 80, both the Powr-Lok™ and Trac-Lok™ were used. Powr-Lok™ differentials were an option for 1994 to very early 1999 model years. Production of Model 80 Powr-Lok™ units and internal gears ceased in 1998. Starting early in the 1999 model year, the Dodge Dana 80 limited slip option was the Trac-Lok™. Externally, Model 80 Powr-Lok™ and Trac-Lok™ cases look similar as both are of a two-piece design, however, they are easily identified by the shape of the cross-shaft pin ends. The Powr-Lok™ pins are oval with one side angled. Trac-Lok™ pin ends are round.
Early 1999 Axle Tags Numbers with a Powr-Lok Diff: 605982, 605983, 605984, 605985, 606064
1999 Axle Tag Numbers with a Trac-Lok Diff: 606150, 606151, 606152, 606153, 606154

Tech Note 3: Design Change
Dana changed the clutch disc components for Dana 80 Trac-Lok differentials around 2003. A Dana factory drawing showing the new disc sequence is included with this Kit.

Tech Note 4: Before Assembly
Limited Slip clutch discs MUST be soaked in limited slip lube or a mix of limited slip lube and gear oil before assembly.

Tech Note 5: Matching Parts
Matching parts for QU40430 Dana 80 Trac-Lok Overhaul Kit are:
QU40096 Ring Gear Bolts
QU40343 Differential Cap Retaining Bolts
QU40306 Axle Shaft Flange Bolts
TK40260 Outboard Differential Bearing Spacers
QU40218 Limited Slip Lubricant
QU40118 Stock Locking Spindle Nut (NEVER reuse stock type spindle nuts)
QU40115 Spindle Nut Lock Wedge (NEVER reuse spindle nut lock wedges)
TK8356 Wheel Bearing Kits for Single Rear Wheels
TK8324 Wheel Bearing Kit for Dual Rear Wheels
QT1032 Differential Case Spreader
Exploded View XV2011 2000-2002 Dodge Ram 2500, Ram 3500 Dana 80 Rear Axle

Tech Note 6: Tech Help
Do the job right the first time. See my 26 page, color illustrated TM4400 Pinion and Differential Bearing Service On Dana-Spicer Monobeam Axles with over 75 photos for the correct differential bearing replacement and adjustment service procedures.

Tech Note 7: Pinion Depth
If you are changing gear sets, your new Pinion Depth must be set before calculating the differential shim pack thicknesses. After setting the pinion depth, use a dial indicator and QT1099 (NLA)Master Bearings to determine the amount of shims required to get the required gear lash and differential bearing preload.

Applications
Dodge Ram 2500 with V-10 or Diesel Engine, a Manual Transmission, and limited slip rear axle: 1999, 2000, 2001, 2002
Dodge Ram 3500 with all engine, transmission combinations and limited slip rear axle: 1999, 2000, 2001, 2002