INSTALLATION GUIDE
Contents
1. n SEE DUAE Ds re US EE Eh e am INSTALLATION s Ce SE a 171 i e Da cius dorm near ee EE a ne p a M pat EE pour TEN pat 408 la Pie a ee M NM Cr M rA Es bet i d S Rp We Keck 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 7 Assembly steps 14 to 39 8 Verification of Proper Assembly Test steps 40 to 44 17 Finish Installation steps 45 to 49 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 IDENTIFICATION TERMINOLOGY Spider Gear Washer 2 Spider Gear 2 Ring Gear C Clip 2 Axle Housing Thrust Washer 2 Bearing Cap 2 Axle Shaft 2 Thrust Block j Differential Case Pinion Shaft Retaining Bolt 2 EXPLODED VIEW Thrust Slug Paddle Opening Saddle Springs 8 in Synchro Paddie N I2. S 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 1013 A Toyota Landcruiser Open Differential 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
3. all the way around Ss 24 Wedge both drivers in engage spring slot ment with couplers Rotate driver s side wheel forward 1 4 turn to reveal spring slot m 25 Place the two inner springs inside 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 check spring 28 Keeping both drivers wedged in df engagement with couplers rotate driver s side wheel forward 1 2 turn N to reveal spring slot on other side L 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 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 Go No G 864 843 9275 There may be a 2 problem with your differential case 32 Push passenger side axle shaft inward through coupler as far as it will go 33 Making sure drivers stay engaged with couplers carefully rotate wheels until c clip slot is accessible Verify c clip groove on axle is accessible through c clip slots on driver and spacer 34 Insert 2nd c clip through c clip slot in driver onto ax
4. e 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 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 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 Reselle
5. il 75W 140 available at your Authorized Richmond Distributor 49 Remove jack stands lower vehicle then remove blocks 18 Notes IMPORTANT INFORMATION Please Read Carefully 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 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 AWWARNING 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 maintenanc
6. le shaft pull axle shaft out to seat c clip 35 Making sure drivers stay engaged with couplers carefully rotate both wheels backwards 1 4 turn to expose pinion shaft opening 36 Feel through pinion shaft open ing and verify both spacers and drivers are fully seated onto cou plers Press down on thrust slugs so that they are seated against the axle ends Verify all 8 saddle springs are fully seated in saddle springs holes pinion shaft opening 15 m 1 MT 16 37 Keeping couplers and drivers stationary rotate case 1 4 turn for ward to align pinion shaft opening with driver saddles 38 Using the retaining bolt as a handle insert the shaft into the dif ferential Press hard while twisting to pass shaft by springs 39 Insert retaining bolt into case shaft Tighten retaining bolt firmly 40 Put transmission in gear or park 41 Turn driver s side wheel forward and hold against driveline for steps 42 amp 43 42 Passenger side wheel should not be able to rotate in the same direction 43 After sharply turning the passenger side wheel in the opposite direction to disengage the unit the wheel should rotate freely 44 Repeat the test for both wheels in both directions iR ARPA em HOLD 17 45 Install differential cover with gasket sealant 46 Add Richmond Synthetic Gear O
7. nner Springs 2 22 Check Block Pinion Shaft Synchro Ring Active Spacer Driver AZ RSA Driver Non Slotted Paddle Opening in Driver N Missing Extended Tooth o Active Spacer 2 Slotted BY RICHMOND Coupler 1 Put transmission in gear or park and turn off engine 2 Set parking brake 4 Safely raise vehicle and apply jack stands 6 Remove Differential cover and drain fluid Clean the diff cover and housing sealing surface 1 Expose pinion shaft remove retaining bolt and shaft Remove thrust block Thrust Block 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 9 Remove both spider gears and their thrust washers 10 Pull axle shafts out approxi mately 6 Remove side gears 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 Install couplers inside differential case ring gear side first 15 Install c clip on ring gear side axle shaft only 16 Make sure paddle opening widest gap in ring gear side syn chro ring is facing out towards you 17 Insert
8. rs 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 TM RICHMOND rsasirguumuses PRODUCTS RING PINIONS LIGHTENED GEARS INSTALLATION KITS REAR END LUBE INSTRUCTIONAL VIDEOS SPOOLS amp MINI SPOOLS j T 1 1 EHERBESENEN n M Br m ow 1 TRANSMISSIONS TRANSMISSION FLUID QUICK CHANGE REAR ENDS CORD REELS SHOPLIGHT
9. the thrust slug into the non slotted spacer Insert the non slotted spacer thrust slug into the non slotted driver Seat the spacer paddle at the paddle opening in driver missing extended tooth 18 Insert driver spacer as shown making sure spacer paddle is facing out towards you ur AAA A 1 p P UL d i NN E i n D U V Y gt ESA A ddle Opening NE 2 NUT lt D 4 d EN A r ON amp ML eh d gt KA K F 1 La E M C 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 y E 20 Insert the thrust slug into the E AY slotted spacer Insert the slotted spacer thrust slug into the slotted driver Seat the spacer paddle at the paddle opening in driver miss ing extended tooth 21 Verify paddle opening widest gap in other synchro ring is facing the back of the differential away from you 10 22 Install slotted driver spacer mak O Ing sure that paddle is pointing U away from you toward rear of differ A ential d Gi A Lua lt PONE 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
Download Pdf Manuals
Related Search