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Richmond Powertrax, Installation Manual

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Richmond Powertrax Installation Manual Download Page 4

Axle Housing

Axle Shaft (2)

Ring Gear

Side Gear (2)

Differential Case

Bearing Cap (2)

Pinion Gear

Thrust Washer (2)

Pinion Shaft

Spider Gear (2)

Pinion Shaft

Retaining Bolt or Roll Pin

C-Clip (2)

2

Spider Gear Washer (2)

Yoke

OPEN DIFFERENTIAL

PART IDENTIFICATION/TERMINOLOGY

Summary of Contents for Powertrax

Page 1: ...INSTALLATION GUIDE TM ...

Page 2: ......

Page 3: ...ential Parts steps 6 to 10 5 Preparation of Parts to be Installed steps 11 to 13 7 Assembly steps 14 to 40 8 Verification of Proper Assembly Test steps 41 to 45 17 Finish Installation steps 46 to 50 18 Thoroughly read User Manual Traction output and resulting handling characteristics of your vehicle will be modified by installation Drive carefully and use caution under all on road and off road con...

Page 4: ... Gear Side Gear 2 Differential Case Bearing Cap 2 Pinion Gear Thrust Washer 2 Pinion Shaft Spider Gear 2 Pinion Shaft Retaining Bolt or Roll Pin C Clip 2 2 Spider Gear Washer 2 Yoke OPEN DIFFERENTIAL PART IDENTIFICATION TERMINOLOGY ...

Page 5: ...d Synchro Ring Coupler 3 Paddle Paddle Opening in Synchro Driver Non Slotted Saddle Springs 8 Active Spacer Paddle Opening in Driver Missing Extended Tooth Active Spacer Inner Springs 2 Outer Springs 2 EXPLODED VIEW Check Block ...

Page 6: ...t 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 ...

Page 7: ... and housing sealing surface 7 Expose pinion shaft remove retaining bolt roll pin and shaft 8 Push both axles inward and remove both c clips Remove o rings from c clip grooves on axle shafts if present Note It may be necessary to remove wheels and disc brake calipers ...

Page 8: ...6 9 Remove both spider gears and their thrust washers 10 Pull passenger side axle shaft out approximately 6 Remove side gears and thrust washers ...

Page 9: ...e aligned with gaps in synchro ring Place coupler in a vise and use an active spacer to align them if necessary 13 Apply wheel bearing grease to saddle springs and seat in holes 12 Apply wheel bearing grease to driver teeth and spacer 7 ...

Page 10: ...e opening widest gap in ring gear side syn chro ring is facing up Paddle Opening 16 Place an active spacer onto the ring gear side coupler as shown Make sure spacer paddle is seated in the paddle opening of the synchro ring and c clip slot is facing out towards you C Clip Slot Spacer Paddle ...

Page 11: ...aft Pull out on wheel to seat the c clip inside the spacer 9 18 Rotate ring gear side wheel 1 4 turn back so that the spacer paddle and the opening in the synchro ring is facing out towards you 19 Insert the non slotted driver as shown making sure the paddle opening in driver missing extended tooth is facing out towards you Spacer Paddle ...

Page 12: ...engaged all the way around 10 21 Insert the second active spacer into the slotted driver Seat the spacer paddle at the paddle open ing in driver missing extended tooth 22 Verify paddle opening widest gap in other synchro ring is facing away from you Paddle Opening ...

Page 13: ...l 11 24 Verify spacer paddle is aligned with the paddle opening in synchro ring and press down on driver spac er to seat on coupler driver teeth should be fully engaged all the way around 25 Wedge both drivers in engage ment with couplers Rotate driver s side wheel forward 1 4 turn to reveal spring slot spring slot ...

Page 14: ...wo inner springs inside the two outer springs 27 Compress inner spring and install spring assembly into spring slot 28 Visually inspect notches in spring slot to make sure inner spring is fully seated 12 check spring ...

Page 15: ... driver s side wheel forward 1 2 turn to reveal spring slot on other side 30 Compress inner spring and install the second spring assembly into the second spring slot 31 Visually inspect notches in spring slot to make sure inner spring is fully seated 13 check spring ...

Page 16: ...ts on driver and spacer 33 Push passenger side axle shaft inward through coupler as far as it will go 32 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 No Go If gap is incorrect STOP and call Powertrax Technical Support at 864 843 9275 There may be a problem with your differential case ...

Page 17: ...p 36 Making sure drivers stay engaged with couplers carefully rotate both wheels backwards 1 4 turn to expose pinion shaft opening 37 Feel through pinion shaft open ing and verify both spacers and drivers are fully seated onto cou plers Verify all 8 saddle springs are fully seated in holes saddle springs pinion shaft opening ...

Page 18: ...olt firmly 39 Using the retaining bolt roll pin as a handle insert the shaft into the differential Press hard while twist ing to pass shaft by springs 38 Keeping couplers and drivers stationary rotate case 1 4 turn for ward to align pinion shaft opening with driver saddles ...

Page 19: ...in the same direction 45 Repeat the test for both wheels in both directions 42 Turn driver s side wheel forward and hold against driveline for steps 43 44 17 HOLD HOLD 44 After sharply turning the passenger side wheel in the opposite direction to disengage the unit the wheel should rotate freely ...

Page 20: ...r with gasket sealant 48 Set parking brake 49 Be sure transmission is in gear or park 50 Remove jack stands lower vehicle then remove blocks 47 Add Richmond Synthetic Gear Oil 75W 140 available at your Authorized Richmond Distributor ...

Page 21: ...Notes ...

Page 22: ...cation plugs and when working close to a unit that has been in operation Check lube level between scheduled lube changes to insure that proper lube level is maintained Inspect vent plug to insure it is clean and operating Inspect the tightness of mounting bolts misalignment of connecting shafts lube leakage excessive heating or any unusual noise or vibration Serious personal injury may occur as a ...

Page 23: ...lowing language in a conspicuous place and in a conspicuous manner in a written agreement covering such sale The manufacturer makes no warranties or representations express or implied by operation of law or otherwise as to the merchantability or fitness for a particular purpose of the goods sold hereunder Buyer acknowledges that it alone has determined that the goods purchased hereunder will suita...

Page 24: ...HI PERFORMANCE PRODUCTS HI PERFORMANCE PRODUCTS RING PINIONS LIGHTENED GEARS INSTALLATION KITS REAR END LUBE INSTRUCTIONAL VIDEOS SPOOLS MINI SPOOLS ...

Page 25: ... Old Norris Road P O Box 238 Liberty S C 29657 Phone 864 843 9231 Fax 864 843 2964 www richmondgear com TRANSMISSIONS TRANSMISSION FLUID QUICK CHANGE REAR ENDS CORD REELS SHOPLIGHTS EXTREME TRACTION SYSTEMS ...

Page 26: ...822 1031 A Dana 35 Open Differential 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 com ...

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