LOCK-RIGHT™ Performance Locker Installation Manual Two- or four-pinion differential; two-piece capped case Typical of Ford® 9-inch 28-, 31-tooth, VW® 002,091, etc. Introduction.................................................................................2 Background Information..............................................................3 Installations Covered....................................................................5 Preliminary Steps..........................................................
manual for reference to instructions about axle removal, torque values, settings, clearances, etc. Our manual is a general guide to operations but does not repeat all the shop manual details. This manual primarily describes the assembly of the two- or four-pinion two-piece differential case that has a cap held on by the ring gear bolts. Some references may be made to the front axle or to 4x4 operation; if your vehicle is a 4x2, ignore them.
Remember: This instruction manual is provided for your convienience to assist you or your mechanic with the installation of your new LOCK-RIGHT. However, the ultimate responsibility for the success of your installation and the subsequent proper operation of your vehicle rest with you, the vehicle owner. When your installation is complete, you will have a vehicle with significantly increased capabilities. For continued “fun in the sun,” operate it in a safe and responsible manner.
( ) = PARTS IN SOME MODELS THRUST WASHER COUPLER (SIDE GEAR) DRIVER STOP PIN; SPACER PINION SHAFT(S) (BLOCK) BIAS SRPINGS Figure 1 LOCK-RIGHT Exploded View 4 DRIVER COUPLER (SIDE GEAR) THRUST WASHER
NOTE: The parts shown in the various figures are typical and may not exactly depict your particular model. e) Disconnecting the brake lines and emergency brake cables (some axles); f) Pulling out both axles a few inches. LOCK-RIGHT Installations Covered in This Manual Capped case differentials, both removable third member axles and integral carrier axles. Typical of these are those in Ford® 9-inch rear axle-equipped vehicles; similar other applications, such as VW® 091, 002, etc.
ring gear end. Mark the carrier and bearing cap on the ring gear side with one punch mark and on the other side with two marks (Figure 2). The caps are not interchangeable! Also mark each bearing adjuster directly under the lock hole with this same mark to note its side and rotational position. This mark is very important to correct re-assembly! 4. Remove the adjuster locks. Be sure that each adjuster is marked at the lock hole with the correct number of punch marks for each side.
. Remove the differential case and ring gear assembly from the carrier along with the other adjuster and bearing race. Inspection of the Parts Disassembly of the Differential Case 1. Remove the ring gear bolts and then the ring gear. It may need to be tapped off with a brass mallet. Mark it so that it can be re-installed in the same rotational position as when removed. Also mark the cap and case so that they can be re-assembled together in the same position. 2. Remove the case cap.
Figure 3 New side gear. Note rough surface and marks Figure 4 Moderately used side gear.
machining marks are still present. Should function properly. c) Heavily used side gear (Figure 5). Note that the tooth surface is highly polished and that the side of the tooth near the top is rolled somewhat flatter. Will not function—should replaced. 3. Inspect the pinion shaft(s) for any galled areas or grooves. If they are not in excellent condition, obtain new ones. 4. Inspect the side gear thrust washers. They are important to the correct positioning of the LOCK-RIGHT parts.
Preparing the Parts for Assembly are hard to insert, use a brass or plastic mallet to drive them to avoid damaging the ends. If the shafts will not insert all the way because the block appears to be too thick, thinner thrust washers will be needed. Either purchase them from your dealer or reduce them in thickness with a surface grinder. Only a few thousandths of an inch may need to be removed. a) Four-pinion case: Place the pinion shaft block into the center of the driver.
Figure 6 Place thrust washer, former top side gear in case Figure 7 Install parts; drive in short shafts and long shafts 11
Figure 8 Install driver, shafts/block; spread shafts apart Figure 9 Drive in long shaft past stub shafts 12
4. Place a bias spring assembly into each deep hole in the bottom driver and place a pin into each of the two other holes. The grease placed in the holes earlier will help hold things in place. 5. Place a bias spring assembly into each deep hole in the other driver and place a pin into each of the other holes. Use grease to help hold them in place (Figure 11). 6. Turn the top driver over and hold it so that the stop pins line up with the springs in the lower driver.
Figure 11 Place springs, pins (with grease) in other driver 14
Install it with ring gear pushed all the way into the drive pinion— that is, with no backlash, and with the bearing races pushed all the way onto the bearings. 4. Check the punch marks on the adjusters and determine which one goes on the side nearest the ring gear. Hold it so that the mark is at its final position (where the lock will be installed, pointing away from the carrier). Push the adjuster against the race and slide it down into the threads in the carrier.
Figure 13 Install other side gear and thrust washer Figure 14 Turn other adjuster to final position; install lock 16
Differential Assembly Inspection When the above steps are completed, all the parts should be in exactly the same positions as they were when the installation began. The backlash and pre-load settings should therefore be unchanged and no further adjustments will be needed. To be certain, rock the ring gear back and forth to see if the backlash appears to be the same as it was prior to the installation. If not, it will need to be reset with a dial indicator as described in the shop manual.
4. Install a gasket and/or sealant as appropriate. 5. Lift the third member into the axle housing 6. Install and torque the hardware. Add gear oil. Note that we suggest using medium-to-heavy oils as recommended by the manufacturer, unless the vehicle will be used in very cold weather. Thicker oil, such as 85-140, reduces the “clicking” noise sometimes heard during tight turns and provides adequate lubrication when the assembly becomes hot.
Driving Your Vehicle more worn than the other one, they both should be replaced for safety reasons. If the foregoing measurements and tests have been successfully completed, apply the emergency brake and remove the vehicle from the jack stands. Your vehicle should now be ready to drive.
Warranty Information The Warranty is contained in the Vehicle Owner’s Manual that is supplied with your new LOCK-RIGHT. Consult this manual for complete warranty information.
IMPORTANT If your differential case or thrust washers are excessively worn, your new LOCK-RIGHT Locker may not be able to operate as it was designed. Therefore, two easy measurements must be made before final assembly to assure that your new locker will function properly. To make these measurements, proceed as follows: 1. Remove the existing spider gears, side gears and thrust washers from the differential case, and thoroughly clean it. 2.
WARNING! IMPORTANT INFORMATION Please Read Carefully •Check lube level between scheduled lube changes to insure that proper lube The following [WARNING] and [CAUTION] information is supplied to you for your protection and to provide you with many years of trouble free and safe operation of your Richmond Gear product. level is maintained. Inspect vent plug to insure it is clean and operating.
CAUTION! •Do not operate the transmission or ring and pinion without proper lube and correct amount.
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