I N S TA L L AT I O N G U I D E TM
Installation Guide Contents Page Limited Slip 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 13) . . . . . . . . . .5 Preparation of Parts to be Installed (steps 14 to 16) . . . . . . . . .8 Assembly (steps 17 to 39) . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIMITED SLIP DIFFERENTIAL PART IDENTIFICATION/TERMINOLOGY Spider Gear (2) Spider Gear Washer (2) Ring Gear C-Clip (2) Axle Housing Clutches Bearing Cap (2) Axle Shaft (2) Clutch Springs Side Gear (2) Differential Case Pinion Shaft Pinion Gear 2 Pinion Shaft Retaining Bolt or Roll Pin
EXPLODED VIEW Thrust Washer (12) Paddle Opening in Synchro Ring Check Block Saddle Spring (8) Paddle Outer Spring (2) Pinion Shaft Coupler (2) Inner Spring (2) Synchro Ring Driver (2) Paddle Opening in Driver (Missing Extended Tooth) Active Spacer (2) 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 and shaft. 8. Push both axles inward and remove both c-clips. Remove orings from c-clip grooves on axle shafts if present.
9. Pull axles out approx. 8”. Mark and remove bearing caps. Note: bearing caps must be reinstalled in their original positions to avoid damage to the gearset or bearings. 10. Remove the differential case from the axle housing. 11. Remove the bearing races and shims. Mark the bearing races and shims. Note: bearing races and shims must be reinstalled onto their original bearings to avoid damage to the gearset or bearings.
12. Remove the bolts holding the two case halves together and separate the two halves. 13. Remove clutches, sidegears, spider gears, spider gear washers, springs, and spring plates. Mark and retain the two cone clutches, they will be reused. Note: cone clutches must be reinstalled in their original positions.
14. 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. 15. Apply wheel bearing grease to driver teeth and spacer. 16. Apply wheel bearing grease to saddle springs and seat in holes.
17. Install the ring gear side clutch and a coupler into the lower half of the differential case. Note: cone clutches must be reinstalled in their original positions. 18. In order to check the clearance inside the differential, temporarily lay the pinion shaft in its slot and insert the wide side of the check block between the coupler face and the pinion shaft. If gap is incorrect, STOP and call Powertrax Technical Support at 864-843-9275. There may be a problem with your differential case. 19.
20. Repeat steps 17 thru 19 for the upper half of the case and clutch. Note how many thrust washers are needed in the upper half of the case. 21. Install the ring-gear side clutch and coupler along with the thrust washers from step 19 into the lower half of the case. Holding the case with the c-clip opening to the left, rotate the coupler so that the paddle opening (widest gap) in the synchro Paddle Opening ring is at the top as shown. 22. Insert a spacer into a driver.
23. Insert driver/spacer as shown, making sure spacer paddle seats in the paddle opening of the synchro ring. Make sure driver and coupler teeth are fully meshed all the way around. 24. Place the two inner springs inside the two outer springs. 25. Insert the springs inside the spring holes in the drivers.
26. Lay the pinion shaft on the driver and case. Align the hole in the shaft with the hole in the case. 27. Insert the second spacer into the second driver. Seat the spacer paddle at the paddle opening in the driver (missing extended tooth). 28. Install second driver/spacer making sure that the c-clip sot in the driver is aligned with the c-clip opening in the case.
29. Insert the second coupler, making sure the paddle opening (widest gap) in the synchro ring is aligned with the paddle on the spacer. Driver and coupler teeth should be fully meshed all the way around. 30. Add the number of thrust washers that were added to the coupler in step 20 and lay the second clutch over the thrust washers. 31. Visually inspect the notches in the spring slots between the drivers to make sure the inner springs are fully seated.
32. Bolt the two halves of the case back together. If there is a gap between the case halves or the case will not go back together, double check the assembly and retry. Do not force the two halves together. 33. Install the bearing races and shims onto their corresponding bearings. Note: bearing races and shims must be reinstalled onto their original bearings to avoid damage to the gearset or bearings. 34.
35. Pull the drilled end of the pinion shaft about 3/4 of the way out. 36. Push in both axles until the c-clip grooves in the axles line up with the c-clip slots in the drivers/spacers. 37. Insert the c-clips onto the axles through the c-clip slots in the drivers/spacers. Pull axles out to seat the c-clips.
38. Using the retaining bolt as a handle, insert the shaft back 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. Passenger side wheel should rotate freely in opposite direction. 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 1033 A Cone Type LSD Integral Carrier C-Clip Version TM P.O. Box 238, 1208 Old Norris Road, Liberty, S.C. 29657 • Tech Support (864)843-9275 • Fax (864)843-1276 • www.richmondgear.
