16
1. Place one of the differential thrust washers (121) onto the 3x25mm cap screw (G).
2. Lubricate the differential thrust washer (121) and then install the plastic thrust ball holder (19) and 1/16" thrust balls
(113) using silicone grease.
3. Lubricate the other differential thrush washer (121) and install it on top of the 1/16" thrust balls (113) and holder (9).
4. Insert the screw and thrust ball assembly into the left outdrive (92).
5. Apply a small amount of grease to one of the differential rings (120) and place it onto the left outdrive (92). The grease
should hold the differential ring (120) in place.
6. Install a 5x9mm bearing (109) onto the left outdrive (92).
7. Install the 3/32" differential balls (112) into the differential gear (18).
8. Install a 5x9mm bearing (109) into the center of the differential gear (18) and install the gear onto the left outdrive (92).
9. Install the other differential ring (120) onto the right differential outdrive (93).
10. Insert the differential spring (123), lock nut holder (22) and the 3mm lock nut (O) into the end of the right differential
outdrive (93).
11. Join the left and right differential outdrives (92&93) together and tighten the 3x25mm cap screw (G) until the differential
gear cannot be turned while both differential outdrives are being held. Note: Be careful not to over tighten the differential.
The differential will require fine tuning once it has been installed into the buggy. (The diff can be properly adjusted by
tightening the diff bolt (G) until snug and then back off 1/8 turn.)
Ball Differential
Note: When installing the bearings make sure they are
fully seated. If the bearings are not fully seated the
gearbox halves may not properly fit together or may
cause binding.
1. Install a 5mm washer (X) onto each end of the top shaft (83).
2. Install a 5x10mm bearing (108) into the upper hole of the
right gearbox half (20).
3. Install the top shaft (83) into the 5x10mm bearing (108)
that was just installed into the right gearbox half (20).
4. Install the 2x10mm spring pin (116) into the top shaft (83)
5. Install a 5x10mm bearing (108) into each side of the idler
gear (17).
6. Install the idler gear shaft (89) into the idler gear bearings.
7. Install the idler gear into the right gearbox half (20).
8. Install a 12x18mm bearing (110) into the lower hole in the
right gear box half (20).
9. Install the ball differential into the 12x18mm bearing (110)
that was just installed into the right gear box half (20).
10. Insert a 12x18mm bearing (110) and 5x10mm bearing (108) into the left gearbox half (21).
11. Install the two gearbox halves (20&21) together. Make sure the two gearbox halves properly fit together.
12. Secure the two halves together with the 4-40x3/8" socket head screw (C).
Gearbox
