Instructions for Dana 80 Trak Lok Rebuild

New clutch design part# 2003819 (Clutches only) / 2003857 (Clutches and Spiders).

NOTE THIS IS TRAK LOK ROUND STYLE PIN, NOT POWER LOK V STYLE PIN!!! D80 POWER LOK (P/L) ARE OBSOLETE AND THE PARTS TO REBUILD ARE NOT AVAIALBLE. 94-98 DODGE IS MOST COMMON APPLICATION FOR D80 P/L.

From left to right:

  1. Eared Steel Plate
  2. Eared Steel Plate
  3. Friction clutch internally splined
  4. Eared Steel plate
  5. Friction Clutch internally splined
  6. Eared Steel Plate
  7. Friction plate 1 side/ steel opposing side (steel side contacts Concave part of preload washer)
  8. Concave washer with convex part against side gear (IE. The ID of the preload washer makes contact against the side gear and the OD makes contact against the plate)
Torque Spec for Trak Lok case halves is 70 ft lbs with red Loctite!!
Clutch plates and gears arranged in order
Dana 80 Trak Lok clutch assembly components

Pictured below is the difference between a Trak Lock cross pin and a Power Lok cross pin.

Top pin is for a Trak Lock, bottom picture is V-Pin Power Lok.

Comparison of Trak Lock cross pin and Power Lok cross pin
Comparison: Trak Lock (top) vs Power Lok V-Pin (bottom)

Contact Information

For further assistance or inquiries, you can reach us at:

East Coast Gear Supply
566 Airport Rd
Louisburg, NC27549

Phone: 919-672-2705
Website: www.EastCoastGearSupply.com