I N S TA L L AT I O N G U I D E TM
Installation Guide Contents Page Open Differential Part Identification & Terminology ......... 2 Powertrax No-Slip Differential Exploded View .................. 3 Vehicle Preparation for Installation (steps 1 to 5) ............. 4 Removal of Open Differential Parts (steps 6 to 11) ........... 5 Preparation of Parts to be Installed (steps 12 to 14) ......... 7 Assembly (steps 15 to 38) .............................................. 8 Verification of Proper Assembly Test (steps 39 to 43) .......
LIMITED SLIP DIFFERENTIAL PART IDENTIFICATION/TERMINOLOGY Spider Gear Washer (2) Ring Gear Spider Gear (2) Thrust Block Axle Housing Thrust Washer (2) Clutches Bearing Cap (2) Axle Shaft (2) Clutch Spring Side Gear (2) Differential Case Pinion Shaft Pinion Gear 2 Pinion Shaft Retaining Clips (2)
EXPLODED VIEW Paddle Opening Paddle in Synchro Saddle Spring (8) Check Block Pinion Shaft Inner Spring (2) Outer Spring (2) Coupler Synchro Ring Driver Active Spacer Half Block Paddle Opening in Driver (Missing Extended Tooth) 3
1. Put transmission in gear (or park), and turn off engine. 2. Set parking brake. 3. Safeguard the vehicle from rolling. 4. Safely raise vehicle and apply jack stands. 5. Put transmission in neutral and release parking brake.
6. Remove differential cover and drain fluid. Clean the diff cover and housing sealing surface. 7. Remove the axle retaining bolts located on the inside of the brake backing plates. Pull out both axle shafts approximately 8”. 8. Expose pinion shaft;remove retaining clips and shaft.
9. Remove clutch spring (some may have multiple coil springs) if present. 10. Remove both spider gears and their thrust washers. 11. Remove side gears, clutches, thrust washers, and thrust block.
12. Verify gaps in coupler teeth are aligned with gaps in synchro ring. Place coupler in a vise and use an active spacer to align them if necessary. 13. Apply wheel bearing grease to driver teeth and spacer. 14. Apply wheel bearing grease to saddle springs and seat in holes.
15. Install coupler inside differential case, ring gear side first. 16. Install other coupler inside differential case.
17. Make sure paddle opening (widest gap) in ring gear side synchro ring is facing out towards you. Paddle Opening 18. Insert a half block into an active spacer. Insert the spacer/half block together in the driver. Seat the spacer paddle at the paddle opening (missing extended tooth) in the driver. 19. Insert driver/spacer/half block as shown, making sure spacer paddle is facing out towards you.
20. Verify spacer paddle is aligned with paddle opening in synchro ring and press driver/spacer down onto coupler. Driver teeth should be fully engaged all the way around. 21. Insert the second half block into the active spacer. Insert the second spacer/half block together in the driver. Seat the spacer paddle at the paddle opening (missing extended tooth) in the driver. 22. Verify paddle opening (widest gap) in other synchro ring is facing the back of the differential, away from you.
23. Install other driver/spacer/half block making sure that paddle is pointing away from you toward rear of differential. 24. Verify spacer paddle is aligned with the paddle opening in synchro ring and press down on driver/spacer to seat on coupler; driver teeth should be fully engaged all the way around. 25. Wedge both drivers in engagement with couplers. Rotate driver’s side wheel forward 1/4 turn to reveal spring slot.
26. Place the two inner springs inside the two outer springs. 27. Compress inner spring and install spring assembly into spring slot. 28. Visually inspect notches in spring slot to make sure inner spring is fully seated.
29. Keeping both drivers wedged in engagement with couplers, rotate driver’s side wheel forward 1/2 turn to reveal spring slot on other side. 30. Compress inner spring and install the second spring assembly into the second spring slot. 31. Visually inspect notches in spring slot to make sure inner spring is fully seated.
32. Check the gap between drivers using check block. The narrow side of the block should fit between the drivers, but the wider side should not fit. Go If gap is incorrect, STOP and call Powertrax Technical Support at 864-843-9275. There may be a problem with your differential case. No Go 33. Making sure drivers stay engaged with couplers, carefully rotate both wheels backwards 1/4 turn to expose pinion shaft opening. pinion shaft opening 34.
35. Keeping couplers and drivers stationary, rotate case 1/4 turn forward to align pinion shaft openings. 36. Insert the shaft into the differential. A screwdriver may be used to twist the shaft while pressing on it to pass shaft by springs. If excessive force is required, the spacer paddle may not be aligned with the paddle opening in synchro ring. Verify alignment and ensure driver/spacer/half block is fully seated on coupler before proceeding.
37. Push axle shafts inward through couplers as far as they will go. The axles should push the thrust block halves together, locking the pinion shaft in place. Bolt axles back to the brake backing plates. 38. Make sure pinion shaft is secure by tapping it in both directions. The pinion shaft should be held securely by the half blocks. Note: For disassembly, remove the axle shafts and the springs between the drivers.
39. Put transmission in gear (or park). 40. Turn driver’s side wheel forward and hold against driveline for steps 41 & 42. HOLD 41. Passenger side wheel should not be able to rotate in the same direction. HOLD 42. After sharply turning the passenger side wheel in the opposite direction (to disengage the unit), the wheel should rotate freely. HOLD 43. Repeat the test for both wheels in both directions.
44. Install differential cover with gasket sealant. 45. Add Richmond Synthetic Gear Oil (75W-140) available at your Authorized Richmond Distributor. 46. Set parking brake. 47. Be sure transmission is in gear or park. 48. Remove jack stands, lower vehicle, then remove blocks.
Notes:
IMPORTANT INFORMATION WARNING Please Read Carefully CAUTION CAUTION information is supplied to you for your protection and The following WARNING and to provide you with many years of trouble free and safe operation of your Richmond Gear product. Read ALL instructions prior to operating transmission and/or ring and pinion. Injury to personnel, transmission or ring and pinion failure may be caused by improper installation, maintenance or operation.
• For safe operation and to maintain the unit warranty, when changing a factory installed fastener for any reason, it becomes the responsibility of the person making the change to properly account for fastener grade, thread engagement, load, tightening torque and the means of torque retention. • Mounting bolts should be periodically checked to ensure that the unit is firmly anchored for proper operation.
HI-PERFORMANCE HI-PERFORMANCE PRODUCTS... PRODUCTS...
TRANSMISSIONS TRANSMISSION FLUID CORD REELS SHOPLIGHTS QUICK CHANGE REAR ENDS EXTREME TRACTION SYSTEMS 1208 Old Norris Road • P.O. Box 238 • Liberty, S.C. 29657 Phone: 864-843-9231 • Fax: 864-843-2964 www.richmondgear.
822 1028 B AMC 20 Limited Slip Differential TM P.O. Box 238, 1208 Old Norris Road, Liberty, S.C. 29657 • Tech Support (864)843-9275 • Fax (864)843-1276 • www.richmondgear.
