4
Slide two Labyrinth Dust Covers onto the ends of the diff shafts; the smooth
sides of the covers face outward, away from the pulley. Squeeze the covers
firmly until they both "snap" onto pulley; it may take a bit of effort to do this.
Once snapped on, the covers seat perfectly.
TToo cchheecckk tthhee ddiiffffeerreennttiiaall::
Slide two wrenches into the slots on both sides of the diff shafts.
Hold both wrenches in one hand and try to turn the pulley; it
should take some force to get the pulley to slip between the two
outdrives. Then remove both wrenches and rotate one of the diff
shafts while holding the pulley stationery. The action should feel
smooth.
To tighten the differential:
Insert a small Allen wrench into the aligned holes in the setscrew
and long diff shaft. Turn the long diff shaft 1/16 to 1/8 of a turn
clockwise to tighten. Remove the Allen wrench and recheck the
diff.
To loosen the differential:
Same as tightening the differential, except turn the long diff shaft
counter-clockwise to loosen.
➊
➋
➌
➍
➌
309020
BB 5x8
DO NOT TIGHTEN THE DIFF COMPLETELY
THE DIFF MUST BE BROKEN IN PROPERLY !
1
1.
Hold the short diff shaft with the installed pulley facing up. Place a #309020 (BB 5x8)
ball-bearing on the center stub, atop the other bearing.
2
2..
Put a very thin coat of grease on the side of a #305082 diff washer, and place it on
the long diff shaft. The washer should seat centered on the long diff shaft, and the layer
of grease will hold it in place.
3
3..
Insert the #305040 diff screw into the top of the long diff shaft as shown, and align
the holes in the screw with the holes in the diff shaft. Slide a small Allen wrench through
the aligned holes in both pieces. The end of the diff screw should protrude from the
center of the diff shaft.
4
4..
Hold the lower diff half upward as shown, and lower the long diff shaft with the screw
pointing down onto the short diff shaft. Carefully thread the diff screw into the center of
the short diff shaft. Keep tightening until the diff washer just touches the diff balls, and
then tighten another 1/4 turn or until you feel some resistance. Remove the Allen wrench.
A
ALLW
WA
AYYSS H
HO
OLLD
D TTH
HEE D
DIIFFFFEERREEN
NTTIIA
ALL VVEERRTTIIC
CA
ALL D
DU
URRIIN
NG
G A
ASSSSEEM
MBBLLYY,, SSO
O TTH
HEE PPA
ARRTTSS SSTTA
AYY
IIN
N A
ALLIIG
GN
NM
MEEN
NTT A
AN
ND
D TTH
HEE D
DIIFFFF BBA
ALLLLSS D
DO
O N
NO
OTT FFA
ALLLL O
OU
UTT..
IIM
MPPO
ORRTTA
AN
NTT:: When you build the differential, do not tighten it fully initially; the differential needs to be broken in properly. When you build the diff
tighten it very gently. When you put the diff in the car and complete the assembly, run the car for a few minutes, tighten the diff a little bit, and then
recheck the diff. Repeat this process several times until you have the diff tightened to the point you want it.
Final adjustments should ALWAYS be made with the diff in the car and on the track.
FRONT & REAR DIFFERENTIAL
Cutaway view
When you need to open the differential,
use the shaft of a wrench to spread
the dust covers apart to pop them off.
Cutaway view
LONG DIFF SHAFT
SHORT DIFF SHAFT
