powr-lok clutches

i have the pdf that shows how the discs are supposed to go but how do you arrange them to make it more like a posi?

 

The various Powr Lok clutch disks can potentially be arranged in many ways.
Each model of axle requires a differing disk arrangement.
In other words the factory disk sequence for a Dana 27 is not the same as for a Dana model 44.
To further complicate things the aggressive disk kit utilizes an extra Bellville in lieu of a flat disk.

So one must determine the model of axle being assembled and also know that aggressive packs are different than standard pack arrangement.
I have disk arrangement charts somewhere but no viable way to upload the pictures.
Maybe I can explain the aggressive D44 arrangement if no one has pics.

 

i only have a pdf for a dana 70 or 60 i think. The axle i have is a dana 44

 

John,
Let me see if I can explain the correct disk plate orientation for your D-44.

First you need to choose a Powr Lok friction disk and plate set.

The kit will be specific for the D44.
Two different kits are available see eBay # 400398928129 (smooth) and # 400396990725 (aggressive)

Depending on kit chosen there are either 3 (with smooth kit) or 4 (with aggressive kit) types of parts in each kit.

1) The Plate has 4 extensions that prevent them from spinning inside the case.
2) The Disk has internal splines and it spins along with the side gear ring.
3) The Belleville Plate is curved in shape and it does not spin inside the case.
4) The Belleville Disk is curved in shape and it spins along with the side gear ring.

These plates and disks are assembled in a particular order for each model of axle.
The correct order also depends upon smooth or aggressive traction ability.


D-44 SMOOTH kit assembly orientation ...
1) Case half
2) Curved Bellville Plate (position the convex away from the case half)
3) Disk
4) Plate
5) Disk
6) Plate
7) Side gear ring
8 ) Side gear

D-44 AGGRESSIVE kit assembly orientation ...
1) Case half
2) Bellville Plate (position the convex away from the case half)
3) Bellville Disk
4) Plate
5) Disk
6) Plate
7) Side gear ring
8 ) Side gear


Each Powr Lok unit consists of 2 case halves.
Repeat the above sequence for each case half.
The case halves are not marked and must be re-assembled in original alignment because the halves were machined in unison.
They can potentially be assembled 180* from original orientation.
Incorrect orientation of the case halves causes the case bolts to bind upon insertion.

 

Yes, there it is.
Only that bulletin does not cover the AGGRESSIVE arrangements

 

wow fantastic!!!!!! now i just need to know the orientation for the aggressive setup

 

are the yukon clutches any good? there doesn't seem to be any spicer brand ones..

 

Don't mean to hijack the thread, are the discs supposed to be steel or steel with friction material?

 

Possibly, I'd have to look through stacks of old Jeep publications.

can't really say .... did you ask Bill's Auto parts if they had any Spicer sets ?

Not really a hijack its the same topic. The friction plates and disks are 100% high carbon (spring) steel.

 

Original discs are spring steel like Oldtime indicated. There are however friction discs offered in the aftermarket with a friction material on them. Stay away. They do not last as long and must be soaked in friction modifier for 24 hours before installing. If you've ever smelled friction modifier, you will want to do this outside, not in a garage. Note: all friction discs should be lubricated during or before installation.

There are many ways to set up Powerlocks depending on how aggressive you want it and how many clutch discs you install. There are different numbers of discs in different kits also. I've set them up light, medium, and aggressive. I've also built special tools to check the breakaway torque so I can set them where I or the customer wants.
Six States Distributing (Spicer dealer) typically has or can get the Dana 44 clutch kit. At least up until this writing to the best of my knowledge. The 30 clutch kits will work with the 25 and 27 but they are getting harder to get also. Be aware the kit you purchase may not have the same number of clutch parts or thicknesses of the factory offerings, even though they are Spicer kits. There are so many variations it would be unrealistic for Spicer to offer all the different options.

 

really wanting the powr-lok to be set up aggressively. it just needs to be put back together before the holiday weekend so i can wheel. after that i'm leaning towards getting an ox locker in the rear and selling the powr-lok. but who knows. maybe the guy never even put new clutches in and with me putting a new set that i know is new it might be what i'm looking for. it doesn't trail ride often but when it does i want the jeep to be able tackle it with little effort.

 

To set up a standard Powr Lok; one only installs a single "Belleville plate" in each of the two clutch packs.
To set up an aggressive Powr Lok you will need an aggressive "Bellville disk" on each side of the two clutch packs.
The Bellville disk is not supplied in the standard friction clutch set.
The aggressive "Bellville disk" is used in place of a standard disk.
The aggressive "Bellville disk" always fits up against the standard Bellville plate.
Otherwise the "aggressive" clutch pack is the same as the "standard" shown on the Bulletin.

I'm only referring to standard and the normal aggressive arrangements.
As Nickmil indicates the clutch packs can potentially be set up any way you want to experiment.

Got that ?

 

Thanks for the answer on the disc material. I happen to be assembling the D44 for my 3A, and was wondering about that. Keeping the thread on the Power Lok, is there a preferred brand of friction modifier to add to the oil? When I did an oil change on the front and rear of my Tux, I used run of the mill limited slip additive from Oreilley's.
Thanks,
John

 

I use Ford brand.
Very smelly stuff.
Don't leave the lid off the container.....

 

I skip the modifier and use "Mobil One" synthetic gear lube.

 

ok here are the clutches that were installed. let me know what y'all think

this is the clutch that is against the case half and the convex was away from the case half..now mind you i have MAYBE 30 miles and that is a big maybe on these clutches.

here is the other side of the same clutch

this is the second clutch... this has a VERY slight and i mean very slight curve to it but it was installed the same way as the first...meaning the convex was the same way..

this is the other side....

this is the third clutch flat only...

the other side of #3...

clutch 4...this looks used to me

other side #4...

#5....

other side of #5

 

i used trans dapt limited slip additive. it didn't stink like you all said. it was a small bottle each in both the front and the rear. after putting that in i drove in figure 8 patterns and circles for about an hour or so in 4 wheel drive. let me tell ya the old arms were sore the next day. after that i took it out wheelin for half a day and then the video i posted in the other thread that shows the one wheel peel. ohh and maybe 4 trips down my road 1 mile max each way.