How-to
2004 Mercury Grand Marquis Trac-Loc Clutch Pack Rebuild
The Trac-Loc differential in a 2004 Mercury Grand Marquis was taken apart and rebuilt with a "+1" clutch pack, going from three friction elements to four while keeping four splined drivers. The photos show the old parts, soaking the new friction elements in friction modifier, measuring both clutch assemblies and setting the new pack in place.
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Step 1
Disassemble the Trac-Loc unit and lay out the old parts for inspection: the clutch pack set with its shim, the pinion pin, the gears and the side gear with its clutch pack. The owner notes the old clutch pack has three friction elements and four splined drivers, in two sets of two.
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Step 2
Soak the new friction elements in friction modifier before assembly.
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Step 3
Measure the thickness of the stock clutch assembly, then measure the "+1" clutch assembly the same way for comparison.
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Step 4
Set the "+1" clutch pack and side gears in place. The owner notes the new stack has four friction elements and four splined drivers.
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Step 5
Set the rebuilt "+1" Trac-Loc carrier and gears into the axle housing, as shown in the final photo. The photos end here, with no further reassembly stages shown.
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