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 16) ........... 5 Preparation of Parts to be Installed (steps 17 to 19) ......... 9 Assembly (steps 20 to 36) .............................................. 10 Verification of Proper Assembly Test (steps 37 to 41) ......
OPEN DIFFERENTIAL PART IDENTIFICATION/TERMINOLOGY Ring Gear Bearing Cap (2) Axle Shaft (2) Axle Housing Yoke Differential Case Pinion Gear 2 Bearing Adjuster Lock (2) Bearing Adjuster (2)
EXPLODED VIEW Paddle Opening in Synchro Pinion Shaft, Long Gage Block Saddle Springs (8) Inner Springs (2) Synchro Ring Outer Springs (2) Gage Ring Driver Pinion Shaft, Short (2) Block Paddle Paddle Notch in Driver 3 Coupler
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. Bearin g Cap 8. Mark the position and orientation of the bearing caps to the housing and bearing adjusters to the adjuster locks. These parts are not interchangeable and must be reinstalled in their original positions.
9. Remove adjuster locks and 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. Loosen the bearing adjusters. 11. Pull out the differential case from the third member. 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.
12. Mark the position of the ring gear to the two halves of the differential case and remove the ring gear. The ring gear must be reinstalled in its original position. 13. Remove the smaller half (cap) of the differential case. The case halves should have been marked in Step 12 as they must be reinstalled in their original position. 14. Remove the side gear and thrust washer.
Spider Spider Gear 15. Remove the spider along with the spider gears and spider gear thrust washers from the case. Spider Gear Thrust Washer 16. Remove the second side gear and thrust washer.
17. 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. 18. Apply wheel bearing grease to driver teeth. 19. Apply wheel bearing grease to saddle springs and seat in holes.
20. Install a coupler into the case. 21. Insert the driver onto the coupler making sure the driver’s notch is aligned with the paddle opening (widest gap) in the synchro ring. The driver and coupler teeth should be fully engaged. Driver Notch 22. 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.
23. In order to check the clearance inside the differential case, temporarily set the second coupler onto the block, 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. cap gage ring 24. 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. If gap is incorrect, STOP and call Powertrax Technical Support at 864-843-9275.
26. Place the two inner springs inside the two outer springs. 27. Place the two spring assemblies into the spring holes (holes with a step) in the driver.
28. Install the second driver into the differential case making sure the notch in the driver is aligned with the block’s paddle. 29. Install the second coupler into the differential case. Make sure paddle opening (widest gap) in synchro ring is aligned with the block’s paddle. 30. Install the cap onto the differential case. Make sure the two case halves line up to their original positions.
31. Install the ring gear back onto the case. Make sure the mark on the ring gear lines up with the mark on the two halves of the case. 32. Place the bearing races on the corresponding bearings and install the assembly in the third member. 33. Tighten bearing adjusters back to their original positions.
34. Reinstall the bearing caps in their original positions. Tighten bearing caps down to required torque and reinstall bearing adjuster locks. 35. Reinstall axle shafts in housing. 36. Reinstall differential cover.
37. Put transmission in gear (or park). 38. Turn driver’s side wheel forward and hold against driveline for steps 39 & 40. HOLD 39. Passenger side wheel should not be able to rotate in the same direction. HOLD 40. After sharply turning the passenger side wheel in the opposite direction (to disengage the unit), the wheel should rotate freely. HOLD 41. Repeat the test for both wheels in both directions.
42. Add Richmond Synthetic Gear Oil (75W-140) available at your Authorized Richmond Distributor. 43. Set parking brake. 44. Be sure transmission is in gear or park. 45. 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 1011 A Open Differential 3rd Member 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.
