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 38) .............................................. 8 Verification of Proper Assembly Test (steps 39 to 43) .......
OPEN DIFFERENTIAL PART IDENTIFICATION/TERMINOLOGY Spider Gear (2) Spider Gear Washer (2) Third Member Ring Gear Thrust Washer (2) Bearing Cap (2) Axle Housing Axle Shaft (2) Yoke Side Gear (2) Differential Case Pinion Shaft Pinion Gear 2 Pinion Shaft Retaining Bolt or Roll Pin
EXPLODED VIEW Paddle Opening in Synchro Check Block Saddle Springs (8) Paddle Inner Springs (2) Pinion Shaft Outer Springs (2) Synchro Ring Active Spacer Driver Paddle Opening in Driver (Missing Extended Tooth) Coupler 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 axle shafts and driveshaft from axle housing. Note: In some cases, this may require you to disconnenct your brake lines and other items. Please consult your vehicle’s repair manual for specific instructions on this step. 7. Remove complete 3rd member from axle housing. 8. Expose pinion shaft; remove retaining bolt/roll pin and shaft. 5 Note: In differentials with very low gear ratios (numericaly high), the ring gear thickness may prevent the removal of the pinion shaft.
9. Remove both spider gears and their thrust washers. 10. Remove both sidegears 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.
14. Insert a coupler into the ring gear side of the case first. 15. Insert the second coupler into the opposite side of the case.
16. Make sure paddle opening (widest gap) in ring gear side synchro ring is facing out towards you. Paddle Opening 17. Insert an active spacer into a driver. Seat the spacer paddle at the paddle opening in the 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 second active spacer into the second driver. Seat the spacer paddle at the paddle opening in the 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 second 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 drivers/couplers 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 drivers/couplers 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. 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 32. Keeping both drivers fully engaged with couplers, rotate drivers/couplers back 1/4 turn to expose pinion shaft opening. 33.
34. Keeping couplers and drivers stationary, rotate case 1/4 turn forward to align pinion shaft openings. 35. Using the retaining bolt/roll-pin as a handle, insert the shaft into the differential. Press hard while twisting to pass shaft by springs. 36. Insert retaining bolt/roll-pin into case/shaft. Tighten retaining bolt firmly.
37. Reinstall 3rd member. 38. Reinstall axle shafts and driveshaft. Note: Please consult your vehicle’s repair manual for specific instructions on this step.
39. Put transmission in gear (or park). 40. Turn driver’s side wheel forward and hold against driveline for steps 41 & 42. HOLD 41. Passenger side wheel should not be able to rotate in the same direction. HOLD 42. After sharply turning the passenger side wheel in the opposite direction (to disengage the unit), the wheel should rotate freely. HOLD 43. Repeat the test for both wheels in both directions.
44. Add Richmond Synthetic Gear Oil (75W-140) available at your Authorized Richmond Distributor. 45. Set parking brake. 46. Be sure transmission is in gear or park. 47. 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 1009 A Open Differential 3rd Member 2-Pinion TM P.O. Box 238, 1208 Old Norris Road, Liberty, S.C. 29657 • Tech Support (864)843-9275 • Fax (864)843-1276 • www.richmondgear.