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 10) ........... 5 Preparation of Parts to be Installed (steps 11 to 13) ......... 7 Assembly (steps 14 to 39) .............................................. 8 Verification of Proper Assembly Test (steps 40 to 44) .......
OPEN DIFFERENTIAL PART IDENTIFICATION/TERMINOLOGY Spider Gear Washer (2) Ring Gear Spider Gear (2) C-Clip (2) Axle Housing Thrust Washer (2) Bearing Cap (2) Axle Shaft (2) Yoke Side Gear (2) Differential Case Thrust Block Pinion Gear Pinion Shaft 2 Pinion Shaft Retaining Bolt
EXPLODED VIEW Check Block Thrust Slug Paddle Opening in Synchro Saddle Springs (8) Paddle Inner Springs (2) Pinion Shaft Outer Springs (2) Synchro Ring Active Spacer (Non-Slotted) Driver (Non-Slotted) Driver (Slotted) Paddle Opening in Driver (Missing Extended Tooth) Active Spacer (Slotted) 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. Expose pinion shaft;remove retaining bolt and shaft. Remove thrust block. Thrust Block 8. Push both axles inward and remove both c-clips. Remove orings from c-clip grooves on axle shafts if present. Note: It may be necessary to remove wheels and disc brake calipers.
9. Remove both spider gears and their thrust washers. 10. Pull axle shafts out approximately 6”. Remove side gears and thrust washers.
11. 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. 12. Apply wheel bearing grease to driver teeth and spacer. 13. Apply wheel bearing grease to saddle springs and seat in holes.
1 14. Install couplers inside differential case, ring gear side first. 2 15. Install c-clip on ring gear side axle shaft only.
16. Make sure paddle opening (widest gap) in ring gear side synchro ring is facing out towards you. Paddle Opening 17. Insert the thrust slug into the non-slotted spacer. Insert the nonslotted spacer/thrust slug into the non-slotted driver. Seat the spacer paddle at the paddle opening in driver (missing extended tooth). 18. Insert driver/spacer as shown, making sure spacer paddle is facing out towards you.
19. 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. 20. Insert the thrust slug into the slotted spacer. Insert the slotted spacer/thrust slug into the slotted driver. Seat the spacer paddle at the paddle opening in driver (missing extended tooth). 21. Verify paddle opening (widest gap) in other synchro ring is facing the back of the differential, away from you.
22. Install slotted driver/spacer making sure that paddle is pointing away from you toward rear of differential. 23. 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. 24. Wedge both drivers in engagement with couplers. Rotate driver’s side wheel forward 1/4 turn to reveal spring slot.
25. Place the two inner springs inside the two outer springs. 26. Compress inner spring and install spring assembly into spring slot. 27. Visually inspect notches in spring slot to make sure inner spring is fully seated.
28. Keeping both drivers wedged in engagement with couplers, rotate driver’s side wheel forward 1/2 turn to reveal spring slot on other side. 29. Compress inner spring and install the second spring assembly into the second spring slot. 30. Visually inspect notches in spring slot to make sure inner spring is fully seated.
31. 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 32. Push passenger side axle shaft inward through coupler as far as it will go. 33. Making sure drivers stay c-clip slot engaged with couplers, carefully rotate wheels until c-clip slot is accessible.
34. Insert 2nd c-clip through c-clip slot in driver onto axle shaft; pull axle shaft out to seat c-clip. 35. Making sure drivers stay engaged with couplers, carefully rotate both wheels backwards 1/4 turn to expose pinion shaft opening. pinion shaft open- 36. Feel through pinion shaft opening and verify both spacers and drivers are fully seated onto couplers. Press down on thrust slugs so that they are seated against the axle ends. Verify all 8 saddle springs are fully seated in saddle springs holes.
37. Keeping couplers and drivers stationary, rotate case 1/4 turn forward to align pinion shaft opening with driver saddles. 38. Using the retaining bolt as a handle, insert the shaft into the differential. Press hard while twisting to pass shaft by springs. 39. Insert retaining bolt into case/shaft. Tighten retaining bolt firmly.
40. Put transmission in gear (or park). 41. Turn driver’s side wheel forward and hold against driveline for steps 42 & 43. HOLD 42. Passenger side wheel should not be able to rotate in the same direction. HOLD 43. After sharply turning the passenger side wheel in the opposite direction (to disengage the unit), the wheel should rotate freely. HOLD 44. Repeat the test for both wheels in both directions.
45. Install differential cover with gasket sealant. 46. Add Richmond Synthetic Gear Oil (75W-140) available at your Authorized Richmond Distributor. 47. Set parking brake. 48. Be sure transmission is in gear or park. 49. 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.
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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 1013 A Toyota Landcruiser Open 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.
