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 40) .............................................. 8 Verification of Proper Assembly Test (steps 41 to 45) .......
LIMITED SLIP DIFFERENTIAL PART IDENTIFICATION/TERMINOLOGY Spider Gear Washer (2) Ring Gear Spider Gear (2) C-Clip (2) 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 Bolt or Roll Pin
EXPLODED VIEW Paddle Opening Paddle in Coupler Saddle Spring (8) Check Block Inner Spring (2) Pinion Shaft Outer Spring (2) Coupler Synchro Ring Driver Driver (Slotted) Active Spacer Paddle Opening in Driver POWERTRAX NO-SLIP TRACTION SYSTEM Active Spacer (Slotted) 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. Expose pinion shaft;remove retaining bolt/roll pin and shaft. 8. Push both axles inward and remove both c-clips. Remove o-rings from c-clip grooves on axle shafts if present.
9. Pull axles out approx. 8” and 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, and thrust washers.
12. Verify gaps in coupler teeth are positioned within 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 & seat in holes.
15. Install couplers inside differential case, ring gear side first. 1 16. Install c-clip on ring gear side axle shaft only.
17. Make sure paddle opening (widest gap) in ring gear side synchro ring is facing out towards you. Paddle Opening 18. Insert the non-slotted spacer into the non-slotted driver. Seat the spacer paddle at the missing extended tooth. 19. Insert driver/spacer 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 slotted spacer into the slotted driver. Seat the spacer paddle at the missing extended tooth. 22. Verify paddle opening (widest gap) in other synchro ring is facing the back of the differential, away from you.
23. Install slotted driver/spacer 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. spring slot 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 inbetween drivers, but the wider side should not fit. If gap is incorrect, STOP and call Powertrax Technical Support at 864-843-9275. There may be a problem with your differential case. Go No-Go 33. Push passenger side axle shaft inward through coupler as far as it will go. 34. Making sure drivers stay c-clip slot engaged with couplers, carefully rotate driver’s side wheel until c-clip slot is accessible.
35. Insert 2nd c-clip through c-clip slot in driver onto axle shaft; pull axle shaft out to seat c-clip. 36. Making sure drivers stay engaged with couplers, carefully rotate both wheels backwards 1/4 turn to expose pinion shaft opening. pinion shaft opening 37. Feel through pinion shaft opening and verify both spacers and drivers are fully seated onto couplers. Verify all 8 saddle springs are fully seated in holes.
38. Keeping couplers and drivers stationary, rotate case 1/4 turn forward to align pinion shaft openings. 39. Using the retaining bolt/rollpin as a handle, insert the shaft into the differential. Press hard while twisting to pass shaft by springs. 40. Insert retaining bolt/roll-pin into case/shaft. Tighten retaining bolt firmly.
41. Put transmission in gear (or park). 42. Turn driver’s side wheel forward and hold against driveline for steps 43 & 44. HOLD 43. Passenger side wheel should not be able to rotate in the same direction. HOLD 44. After sharply turning the passenger side wheel in the opposite direction (to disengage the unit), the wheel should rotate freely. HOLD 45. Repeat the test for both wheels in both directions.
46. Install differential cover with gasket sealant. 47. Add Richmond Synthetic Gear Oil (75W-140) available at your Authorized Richmond Distributor. 48. Set parking brake. 49. Be sure transmission is in gear or park. 50. 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 1004 A Limited Slip Differential Integral Carrier C-Clip Version P.O. Box 238, 1208 Old Norris Road, Liberty, S.C. 29657 • Tech Support (864)843-9275 • Fax (864)843-1276 • www.richmondgear.
