I N S TA L L AT I O N G U I D E
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 14) ........... 5 Preparation of Parts to be Installed (steps 15 to 17) ......... 8 Assembly (steps 18 to 32) .............................................. 9 Verification of Proper Assembly Test (steps 33 to 37) .......
OPEN DIFFERENTIAL PART IDENTIFICATION/TERMINOLOGY Ring Gear Bearing Cap (2) Axle Shaft (2) Axle Housing Differential Case Yoke Pinion Gear 2
EXPLODED VIEW Gage Block Saddle Springs (8) Paddle Opening in Synchro Outer Springs (2) Synchro Ring Inner Springs (2) Paddle Gage Ring Pinion Shaft (3) Paddle Notch in Driver Block Driver (2) 3 Coupler (2)
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 axle shafts from housing. Bearing Cap 8. Mark the position and orientation of the bearing caps to the housing. These parts are not interchangeable and must be reinstalled in their original positions.
9. Remove bearing caps from the housing. These parts should have been marked in Step 8 as they are not interchangeable and must be reinstalled in their original positions. 10. Pull the differential case out from the housing. Remove the bearing races from the bearings and mark them. The bearing races must be installed on the same bearings they were originally on to avoid bearing failure. 11. Mark the two halves of the differential case as they must be reinstalled in their original position.
12. Remove the side gear and thrust washer. Thrust Washer Side Gear Spider 13. Remove the spider along with the spider gears and spider gear thrust washers from the case. Spider Gear 14. Remove the second side gear and thrust washer.
15. Verify gaps in coupler teeth are aligned with gaps in synchro ring. Place coupler in a vise and use the pinion shaft block to align them if necessary. 16. Apply wheel bearing grease to driver teeth. 17. Apply wheel bearing grease to saddle springs and seat in holes.
18. Install a coupler into the lower half of the case. 19. Insert block onto the coupler. Make sure the block’s paddle is aligned with the paddle opening in the synchro. Paddle 20. In order to check the clearance inside the differential case, temporarily set the second coupler onto the block, making sure the block’s paddle fits into the opening in the synchro, and place the gage ring and cap onto the coupler as shown. There should be a gap between the two halves of the differential case.
21. Check the gap in the differential case using the gage block. The narrow side of the block should fit in the gap, but the wider side should not fit. Go No Go If gap is incorrect, STOP and call Powertrax Technical Support at 864-843-9275. There may be a problem with your differential case. 22. If the gap is correct, remove the cap, gage ring, and coupler to proceed. 23. Insert the driver onto the coupler making sure the driver’s notch is aligned with the paddle on the block.
24. Lift the block and insert the pinion shafts into the block (small diameters facing outwards) and insert the block with the pinion shafts into the case. Make sure the block’s paddle passes through the driver notch and seats in the paddle opening (widest gap) in the synchro ring. 25. Place the two inner springs inside the two outer springs. 26. Place the two spring assemblies into the spring holes (holes with a step) in the driver.
27. Install the second driver into the differential case making sure the notch in the driver is aligned with the block’s paddle. 28. Install the second coupler into the differential case. Make sure paddle opening (widest gap) in synchro ring is aligned with the block’s paddle. The driver and coupler teeth should be fully engaged all the way around. 29. Install the cap onto the differential case. Make sure the two case halves line up to their original positions.
30. Place the bearing races on their corresponding bearings and install the assembly in the housing. 31. Reinstall the bearing caps in their original positions. Tighten bearing caps down to required torque. 32. Reinstall axle shafts in housing.
33. Put transmission in gear (or park). 34. Turn driver’s side wheel forward and hold against driveline for steps 35 & 36. HOLD 35. Passenger side wheel should not be able to rotate in the same direction. HOLD 36. After sharply turning the passenger side wheel in the opposite direction (to disengage the unit), the wheel should rotate freely. HOLD 37. Repeat the test for both wheels in both directions.
38. Install differential cover with gasket sealant. 39. Add Richmond Synthetic Gear Oil (75W-140) available at your Authorized Richmond Distributor. 40. Set parking brake. 41. Be sure transmission is in gear or park. 42. Remove jack stands, lower vehicle, then remove blocks.
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 1034 A Open Differential 3 Pinion with Spider TM P.O. Box 238, 1208 Old Norris Road, Liberty, S.C. 29657 • Tech Support (864)843-9275 • Fax (864)843-1276 • www.richmondgear.
