 The following information is
provided by
Richmond
Gear. These instructions are the instructions we followed during
our installation of the Powertrax No-Slip Differential in a 30 spline Dana
44 Axle. These instructions are posted for educational purposes only
and are not meant to be THE instructional guide to installing the
Powertrax No-Slip Differential, rather as a review of the process
transcribed into an HTML format. Please refer to
Richmond Gear
for your application of the Powertrax No-Slip Differential as well as many
other great products. Source: Richmond Performance Products, 822
1003 A, Open Differential Integral Carrier Non C-Clip Version
Richmond Performance Products • 1208 Old
Norris Road • P.O. Box 238 • Liberty, S.C. 29657 •
Phone: 864-843-9231 • Fax: 864-843-2964 On the web at:
www.richmondgear.com
Powertrax No-Slip Differential
Installation Guide
Contents
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| 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 conditions.
|
IMPORTANT
INFORMATION
Please Read CarefullyThe following
and information is supplied to you for your protection 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.
DANGER
- It is dangerous to get under a jacked-up
vehicle. The vehicle could slip off the jack and fall on you. You could
be crushed. Never place any part of your body under a vehicle that is on
a jack. Never start or run the engine while the vehicle is on a jack. If
you need to get under a raised vehicle, take it to a service center
where it can be raised on a lift.
WARNING
- Hot oil can cause severe burns. Use extreme
care when removing lubrication 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 result
of improperly performed maintenance, adjustments or repairs.
- Do not attempt any of the maintenance, checks
or repairs described on the following pages if you are not fully
familiar with these or other procedures with respect to the
transmission, or are uncertain as to how to proceed. Have the necessary
work done by a properly equipped and qualified workshop.
- Always be extremely careful when working on the
transmission. Always follow commonly accepted safety practices and
general common sense. Never risk personal injury.
CAUTION
- Do not operate the transmission or ring and
pinion without proper lube and correct amount.
- 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.
- These instructions are not intended to cover
all details or variations in equipment, nor provide for every possible
contingency to be met in connection with selection, installation,
operation, and maintenance. Should further information be desired or
should particular problems arise which are not covered sufficiently for
the Buyer’s purpose, the matter should be referred to Richmond Gear.
In the event of the resale of any of the goods, in
whatever form, Resellers/Buyers will include the following 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 suitably meet the requirements
of their intended use. In no event will the manufacturer be liable for
consequential, incidental or other damages. Even if the repair or
replacement remedy shall be deemed to have failed of its essential
purpose under Section 2-719 of the Uniform Commercial Code, the
manufacturer shall have no liability to Buyer for consequential damages.
Resellers/Buyers agree to also include this entire
document including the danger, warnings and cautions above in a
conspicuous place and in a conspicuous manner in writing to instruct users
on the safe usage of the product.
This information should be read together with all
other printed information supplied by Richmond Gear.
|
1208 Old Norris Road • P.O.
Box 238 • Liberty, S.C. 29657
Phone: 864-843-9231 • Fax: 864-843-2964
www.richmondgear.com
Source:
Richmond Performance Products
822 1003 A
Open Differential
Integral Carrier
Non C-Clip Version |
| |
|
OPEN
DIFFERENTIALPART IDENTIFICATION/TERMINOLOGY
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POWERTRAX NO-SLIP EXPLODED VIEW
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Vehicle
Preparation for Installation (steps 1 to 5)
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| 1. Put transmission in gear (or park), and turn
off engine. |
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| 2. Set parking brake. |
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| 3. Safeguard the vehicle from rolling. |
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| 4. Safely raise vehicle and apply jackstands. |
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| 5. Put transmission in neutral and release
parking brake. |
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|
Removal of Open
Differential Parts (steps 6 to 11)
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| 6. Remove Differential cover and drain fluid.
Clean the diff cover and housing sealing surface.
|
 |
| 7. Expose pinion shaft; remove retaining pin/roll
pin. Remove pinion shaft.
Note: In differentials with very low gear
ratios (numerically high), the ring gear thickness may prevent the removal
of the pinion shaft. If this occurs, the differential case must be removed
from the car and the ring gear must be taken off before proceeding. Please
refer to your vehicle’s repair manual for instructions on how to remove
the case and ring gear.
|
 |
| 8. Remove the axle retaining bolts for the
passenger side axle shaft located on the inside of the brake backing
plate. Pull out passenger side axle shaft 2”-3”. |
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| 9. Remove both spider gears and their thrust
washers. |
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| 10. Remove passenger-side side gear and thrust
washer. |
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| |
| 11. Remove remaining side gear and thrust washer. |
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|
Preparation
of Parts to be Installed (steps 12 to 13)
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| 12. Verify gaps in coupler teeth are positioned
within gaps in synchro ring. Place coupler in a vise and use an active
spacer to align them if necessary. |
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| 13. Apply wheel bearing grease to driver teeth
and spacer. |
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|
Assembly (steps 14 to 36)
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| 14. Apply wheel bearing grease to saddle springs
& seat in holes. |
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| 15. Insert the a coupler into the ring gear side
of the case first. |
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| 16. Insert the second coupler into the opposite
side of the case. |
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| 17. Make sure paddle opening (widest gap) in ring
gear side synchro ring is facing out towards you. |
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| 18. Insert an active spacer into a driver. Seat
the spacer paddle at the missing extended tooth. |
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19. Insert driver/spacer as shown, making sure
spacer paddle is facing out towards
you. |
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20. 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. |
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| 21. Insert the second active spacer into the
second driver. Seat the spacer paddle at the missing extended tooth. |
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| 22. Verify paddle opening (widest gap) in other
synchro ring is facing the back of the differential, away from you. |
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| 23. Install second driver/spacer making sure that
paddle is pointing away from you toward rear of differential. |
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| 24. 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. |
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| 25. Wedge both drivers in engagement with
couplers. Rotate driver’s side wheel forward 1/4 turn to reveal spring
slot. |
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| 26. Place the two inner springs inside the two
outer springs. |
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| 27. Compress inner spring and install spring
assembly into spring slot. |
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| 28. Visually inspect notches in spring slot to
make sure inner spring is fully seated. |
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| 29. Keeping both drivers wedged in engagement
with couplers, rotate driver’s side wheel forward 1/2 turn to reveal
spring slot on other side. |
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| 30. Compress inner spring and install the second
spring assembly into the second spring slot. |
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| 31. Visually inspect notches in spring slot to
make sure inner spring is fully seated. |
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| 32. Check the gap between drivers using check
block. The narrow side of the block should fit in between 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.
|
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| 33. Push passenger side axle shaft inward through
coupler as far as it will go and bolt axle shaft back to housing. |
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| 34. Keeping both drivers fully engaged, rotate
both wheels back 1/4 turn to expose pinion shaft opening. Make sure saddle
springs are all fully seated. |
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| 35. Keeping couplers and drivers stationary,
rotate case 1/4 turn forward to align pinion shaft openings. |
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| 36. Using the retaining bolt/roll-pin as a
handle, insert the shaft into the differential. Press hard while twisting
to pass shaft by springs. |
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Verification
of Proper Assembly Test (steps 37 to 42)
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| 37. Insert retaining bolt/roll-pin into
case/shaft. |
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| 38. Put transmission in gear (or park). |
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| 39. Turn driver’s side wheel forward and hold
against driveline for steps 40 & 41. |
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| 40. After sharply turning the passenger side
wheel in the opposite direction (to disengage the unit), the wheel should
rotate freely. |
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| 41. Passenger side wheel should rotate freely in
opposite direction. |
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| 42. Repeat the test for both wheels in both
directions. |
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Finish
Installation (steps 43 to 47)
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| 43. Install differential cover with gasket
sealant. |
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44. Add Richmond Synthetic
Gear Oil (75W-140) available
at your Authorized Richmond
Distributor. |
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| 45. Set parking brake. |
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| 46. Be sure transmission is in gear or park. |
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| 47. Remove jack stands, lower vehicle, then
remove blocks. |
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|
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