Dana 60 Power Lok

Why is that because of the bearings?

I would start with the track lock only uses two spider gears and a single pin through it and the power lock uses four spider gears and has two pins going through it.

So without looking I would say that the size of the gears internally is different but that's just my guess at the moment. One of these days when I feel better I'll throw them up on the bench and look them both over.