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 17) ........... 5 Preparation of Parts to be Installed (steps 18 to 20) ......... 9 Assembly (steps 21 to 46) .............................................. 10 Verification of Proper Assembly Test (steps 47 to 51) ......
GOV LOK DIFFERENTIAL PART IDENTIFICATION/TERMINOLOGY Spider Gear (2) Spider Gear Washer (2) Ring Gear C-Clip (2) Tumbler Clutches Thrust Washer (2) Plugs (2) Bearing Cap (2) Axle Shaft (2) Counterwieght Axle Housing Side Gear (2) Differential Case Pinion Shaft Pinion Gear 2 Pinion Shaft Retaining Bolt
EXPLODED VIEW Paddle Opening in Synchro Ring Coupler (Thick) Extractio n Tool Saddle Spring (8) Check Block Paddle Pinion Shaft Inner Spring (2) Outer Spring (2) Coupler (Thin) Synchro Ring Driver (Non Slotted) Active Spacer (Non Slotted) Driver (Slotted) Paddle Opening in Driver (Missing Extended Tooth) 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 and shaft. 8. Push both axles inward and remove both c-clips.
9. Pull axles out approx. 8”. 10. Mark the bearing cap on the passenger side and remove it. The bearing cap must be reinstalled in its original position. 11. Assemble the enclosed extraction tool as shown.
12. Use the extraction tool to remove the tumbler and counterweight plugs. A wrench may be needed to hold the tool in place. 13. Remove the counterweight and tumbler assemblies from the differential. 14. Remove the block.
15. Remove the spider gears and spider gear thrust washers. 16. Remove the sidegears, clutches, and thrustwashers from the differential. 17. Reinstall the bearing cap in its original position and tighten to required torque.
18. 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. 19. Apply wheel bearing grease to driver teeth and spacer. 20. Apply wheel bearing grease to saddle springs and seat in holes.
21. Install couplers inside differential case, thick coupler on ring gear side first. 1 22. Install c-clip on ring gear side axle shaft only.
23. Make sure paddle opening (widest gap) in ring gear side synchro ring is facing out towards you. Paddle Opening 24. Insert the non-slotted spacer into the non-slotted driver. Seat the spacer paddle at the paddle opening in the driver (missing extended tooth). 25. Insert driver/spacer as shown, making sure spacer paddle is facing out towards you.
26. 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. 27. Insert the slotted spacer into the slotted driver. Seat the spacer paddle at the paddle opening in the driver (missing extended tooth). 28. Verify paddle opening (widest gap) in other synchro ring is facing the back of the differential, away from you.
29. Install slotted driver/spacer making sure that paddle is pointing away from you toward rear of differential. 30. 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 31. Wedge both drivers in engagement with couplers. Rotate driver’s side wheel forward 1/4 turn to reveal spring slot.
32. Place the two inner springs inside the two outer springs. 33. Compress inner spring and install spring assembly into spring slot. 34. Visually inspect notches in spring slot to make sure inner spring is fully seated.
35. Keeping both drivers wedged in engagement with couplers, rotate driver’s side wheel forward 1/2 turn to reveal spring slot on other side. 36. Compress inner spring and install the second spring assembly into the second spring slot. 37. Visually inspect notches in spring slot to make sure inner spring is fully seated.
38. 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. 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 39. Push passenger side axle shaft inward through coupler as far as it will go. 40. Making sure drivers stay engaged with couplers, carefully rotate driver’s side wheel until c-clip slot is accessible.
41. Insert 2nd c-clip through c-clip slot in driver onto axle shaft; pull axle shaft out to seat c-clip. 42. Making sure drivers stay engaged with couplers, carefully rotate both wheels backwards 1/4 turn to expose pinion shaft opening. pinion shaft opening 43. Feel through pinion shaft open- saddle springs ing and verify both spacers and drivers are fully seated onto couplers. Verify all 8 saddle springs are fully seated in holes.
44. Keeping couplers and drivers stationary, rotate case 1/4 turn forward to align pinion shaft openings. 45. Using the retaining bolt as a handle, insert the shaft into the differential. Press hard while twisting to pass shaft by springs. If excessive force is required, the spacer paddle may not be aligned with the paddle opening in synchro ring. Verify alignment and ensure driver/spacer/half block is fully seated on coupler before proceeding. 46. Insert retaining bolt into case/shaft.
47. Put transmission in gear (or park). 48. Turn driver’s side wheel forward and hold against driveline for steps 49 & 50. HOLD 49. Passenger side wheel should not be able to rotate in the same direction. HOLD 50. After sharply turning the passenger side wheel in the opposite direction (to disengage the unit), the wheel should rotate freely. HOLD 51. Repeat the test for both wheels in both directions.
52. Install differential cover with gasket sealant. 53. Add Richmond Synthetic Gear Oil (75W-140) available at your Authorized Richmond Distributor. 54. Set parking brake. 55. Be sure transmission is in gear or park. 56. 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 1007 A Gov-Lok Differential 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.
