INSTALLATION GUIDE
Contents
1. Installation Guide Contents Page Open Differential Part Identification amp 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 T Assembly steps 14 to 38 8 Verification of Proper Assembly Test steps 39 to 43 17 Finish Installation steps 44 to 47 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 conditions OPEN DIFFERENTIAL PART IDENTIFICATIONTERMINOLOGY Spider Gear Washer 2 Spider Gear 2 Ring Gear Third Member Thrust Washer 2 ZX Z Z gt lt Bearing Cap 2 Axle Shaft 2 Axle Housing Differential Case Pinion Shaft Pinion Gear Retaining Bolt or Roll Pin Pinion Shaft 2 EXPLODED VIEW Paddle Opening Saddle Springs 8 in Synchro Paddle Inner Springs 2 a D 1 Pinion Shaft W Check Block Sos I y Synchro Ring Active Spacer Driver Paddle Opening in Driver Missing Extended Tooth BY RICHMOND Coupler 1 Put transmission in gear or park and turn off engin2. Press hard while twist ing 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 drive shaft 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 amp 42 41 Passenger side wheel should not be able to rotate in the same direction 42 After sharply turning the passenger side wheel in the opposite direction to disen gage the unit the wheel should rotate freely 43 Repeat the test for both wheels in both directions 17 44 Add Richmond Synthetic Gear Oil 5W 140 available at your Authorized Richmond Distributor 46 Be sure transmission is in gear or park 4 Remove jack stands lower vehicle then remove blocks 18 Notes IMPORTANT INFORMATION Please Read Caretully The 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 e It is dangerous to get under a jacked up vehicle The vehicl
3. e 2 Set parking brake 4 Safely raise vehicle and apply jack stands 6 Remove axle shafts and driveshaft from axle housing Note In some cases this may require you to dis connenct 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 Note In differentials with very low gear ratios numericaly high the ring gear thick ness may prevent the removal of the pinion shaft If this occurs the differential case must be removed from the 3rd member and the ring gear must be taken off before pro ceding Please refer to your vehicle s repair manual for instructions on how to remove the case and ring gear 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 syn chro ring is faci
4. e 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 AMWARNING e 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 e 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 e Serious personal injury may occur as a result of improperly performed maintenance adjustments or repairs e 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 e Always be extremely careful when working on the transmission Always follow commonly accepted safety practices and general common sense Never risk personal injury e Do not operate the transmission or ring and pinion without proper lube and correct amount e For safe operation and to maintain t
5. he 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 e Mounting bolts should be periodically checked to ensure that the unit is firmly anchored for proper operation e 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 t
6. ng out towards you Fn Ee i m 4 WR m A 3 V E d y A S S Pi oe Paddle Opening UN ee _ VW 17 Insert an active spacer into a driver Seat the spacer paddle at the paddle opening in the driver missing extended tooth A LI e 18 Insert driver spacer as shown A making sure spacer paddle is facing ER II out towards you i PA ie W P Tt E MI Ke 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 open ing 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 Paddle Opening 10 TERET E ae v d 3X Spring slot 22 Install second driver spacer making sure that paddle is pointing away from you toward rear of differ ential 23 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 24 Wedge both drivers in engage ment with couplers Rotate driv ers couplers forward 1 4 turn to reveal spring slot 25 Place the two inner springs i
7. nside 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 check spring 13 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 32 Keeping both drivers fully engaged with couplers rotate driv ers couplers back 1 4 turn to expose pinion shaft opening 33 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 Pinion shaft opening Saddle Springs 14 ee V SUA IP My Ay Ou 5 34 Keeping couplers and drivers Stationary rotate case 1 4 turn for ward to align pinion shaft openings 35 Using the retaining bolt roll pin as a handle insert the shaft into the differential
8. o 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 RICHMOND ureaiirgnuumuses PRODUCTS RING 8 PINIONS LIGHTENED GEARS INSTALLATION KITS REAR END LUBE INSTRUCTIONAL VIDEOS SPOOLS amp MINI SPOOLS su m m mu G EG j 1 w TRANSMISSIONS TRANSMISSION FLUID OUICK CHANGE REAR ENDS CORD REELS SHOPLIGHTS EXTREME TRACTION SYSTEMS 1208 Old Norris Road PO Box 238 Liberty S C 29657 Phone 864 843 9231 Fax 864 843 2964 www richmondgear com 822 1009 A Open Differential 3rd Member 2 Pinion BY S RICHIOND 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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