INSTALLATION GUIDE
Contents
1. HO ar GY YHA 7 eda oS par pair E ERT TEIE x 1 iN Depp DH Tm CER hn URS i PEU cen xul E m i SEES ERES e uu v INSTALLATION GUIDE ra euet Pr z AE P m a 1 z 7 a E iy a n u i n n m rm a a 2 i voee OLTRE agen tru HD Y LEE oan d A CE cip Ur RIDE I TEMBITR T viu LM AL i M LITE we DEL i DE et hb 25 Mw E Leer erint dynu TES Y p 4 A y A y 4 nd 7 Maw on ES ri aT DEDE AE jn 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 11 5 Preparation of Parts to be Installed steps 12 to 14 Assembly steps 15 to 37 8 Verification of Proper Assembly Test steps 38 to 42 16 Finish Installation steps 43 to 47 17 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 DIF2. wheel forward 1 4 turn to reveal spring slot 11 07 Sees spring slot 26 Place the two inner springs inside the two outer springs 2 Compress inner spring and install spring assembly into spring slot 28 Visually inspect notches in spring slot to make sure inner spring is fully seated check spring 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 30 Compress inner spring and install the second spring assembly into the second spring slot Sr 31 Visually inspect notches in spring slot to make sure inner spring is fully seated check spring 32 Check the gap between driv ers using check block The nar row side of the block should fit 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 33 Push passenger side axle shaft inward through coupler as far as it will go The axle shaft should push the thrust block against the opposite axle shaft Bolt axle shaft back to housing N 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 and the pinion ET shaft opening in the thrust block is Pinion MM Shan aligned with the pinion shaft ope
3. FERENTIAL PART IDENTIFICATION TERMINOLOGY Spider Gear Washer 2 Spider Gear 2 Ring Gear Axle Housing Thrust Washer 2 Axle Shaft 2 Side Gear 2 Thrust Block Differential Case Pinion Shaft Pinion Gear Holl Pin 2 EXPLODED VIEW Check Block Paddle Opening Saddle Springs 8 in Synchro Paddle N Inner Springs 2 Yo wy Synchro Ring Active Spacer Driver Paddle Opening in Driver Missing Extended Tooth O BY lt 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 7 Expose pinion shaft use a punch to drive out roll pin Remove pinion shaft 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 Slide thrust block to the right into the side gear 9 Remove both spider gears and their thrust washers 10 Remove passenger side side gear thrust block thrust washer together Retain thrust block 11 Remove remaining side gear and thrust washer 12 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 13 Apply wheel bearing grease to driv
4. ate 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 eguipment 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 manufact
5. er teeth and spacer 14 Apply wheel bearing grease to saddle springs and seat in holes 15 Insert the thrust block into the coupler that will go on the axle shaft opposite the ring gear 16 Insert the coupler into the ring gear side of the case first Insert the coupler with thrust block into the side opposite the ring gear 17 Make sure paddle opening widest gap in ring gear side syn chro ring is facing out towards you 18 Insert an active spacer into a driver Seat the spacer paddle at the paddle opening in driver miss ing extended tooth 19 Insert driver spacer as shown making sure the spacer paddle is facing out towards you 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 21 Insert the second active spacer into the second driver Seat the spacer paddle at the paddle open ing in driver missing extended tooth 22 Verify paddle opening widest gap in other synchro ring is facing away from you 10 23 Install second driver spacer making sure the spacer paddle is pointing away from you 24 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 25 Wedge both drivers in engage ment with couplers Rotate driver s side
6. n Saddle ing in the drivers Springs opening 14 35 Keeping couplers and drivers stationary rotate case 1 4 turn for ward to align pinion shaft openings gt 36 Using the roll pin as a handle insert the shaft into the differential Press hard while twisting to pass shaft by springs iN l A Y 37 Drive roll pin into case shaft 38 Put transmission in gear or park 39 Turn driver s side wheel forward and hold against driveline for steps 40 amp 41 40 Passenger side wheel should not be able to rotate in the same direction 41 After sharply turning the passenger side wheel in the opposite direction to disengage the unit the wheel should rotate freely 42 Repeat the test for both wheels in both directions E em HOLD 16 43 Install differential cover with gasket sealant 44 Add Richmond Synthetic Gear Oil 75W 140 available at your Authorized Richmond Distributor 47 Remove jack stands lower vehicle then remove blocks 17 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 cau
7. sed by improper installation maintenance or operation 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 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 oper
8. urer be liable for conseguential 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 rsirguumuses PRODUCTS RING amp PINIONS LIGHTENED GEARS INSTALLATION KITS REAR END LUBE INSTRUCTIONAL VIDEOS SPOOLS amp MINI SPOOLS m mmu mu EE 1 a See eee eee n s Br m uF TRANSMISSIONS TRANSMISSION FLUID QUICK CHANGE REAR ENDS 0 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 1022 A AMC 20 Open Differential BY GSROHOND 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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