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 17 5 Preparation of Parts to be Installed steps 18 to 20 9 Assembly steps 21 to 46 10 Verification of Proper Assembly Test steps 47 to 51 19 Finish Installation steps 52 to 56 20 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 GOV LOK DIFFERENTIAL PART IDENTIFICATION TERMINOLOGY Spider Gear Washer 2 Spider Gear 2 Ring Gear C Clip 2 Tumbler Thrust Washer 2 Clutches Plugs 2 Bearing Cap 2 Axle Housing e Side Gear 2 Pinion Shaft Differential Case Retaining Bolt 2 EXPLODED VIEW crac n Too Paddle Opening Coupler Thick Saddle Check in Synchro Ring Spring 8 Block Paddle Pinion Shaft LE Inner CP Spring E Outer gt SE Spring 2 ALA Synchro Ring Driver Non Slotted Driver Slotted Active Spacer Non Slotted Paddle Opening in Driver Missing Ext2. _ aN AN e ing slot y 4 R 13 32 Place the two inner springs inside the two outer springs 33 Compress inner spring and install spring assembly into spring slot 0 34 Visually inspect notches in spring slot make sure inner spring is fully seated check spring 35 Keeping both drivers wedged in engagement with couplers rotate driver s side wheel forward 1 2 turn to reveal spring slot on other side 36 Compress inner spring and install the second spring assembly into the second spring slot 37 Visually inspect notches in spring slot to make sure inner spring is fully seated check spring 15 38 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 gap is incorrect STOP and call Powertrax Technical Support at There may be a 864 843 9275 problem with your differential case 39 Push passenger side axle shaft inward through coupler as far as it will go 40 Making sure drivers stay engaged with couplers carefully rotate driver s side wheel until c clip slot is accessible Verify c clip groove on axle is accessible through c clip slots on driver and spacer 16 41 Insert 2nd c clip through c clip slot in driver onto axle shaft pull axle shaft out to seat c clip 4 42 Making sure drivers stay N fs engaged with couplers carefu
3. TREME 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 1007 A Gov Lok Differential Integral Carrier C Clip Version BY SRCHNOND P O Box 238 1208 Old Norris Road Liberty S C 29657 Tech Support 864 843 9275 Fax 864 843 1276 e www richmondgear com
4. d 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 RICHMOND HI PENRFOMIMANCE 2215 RING amp PINIONS LIGHTENED GEARS INSTALLATION KITS REAR END LUBE INSTRUCTIONAL VIDEOS SPOOLS amp MINI SPOOLS TRANSMISSIONS TRANSMISSION FLUID QUICK CHANGE REAR ENDS CORD REELS SHOPLIGHTS EX
5. ended Tooth POWERTRAX Active Spacer i Slotted No Slip Traction System 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 remove retaining bolt and shaft 8 Push both axles inward and remove both c clips 9 Pull axles out approx 8 10 Mark the bearing cap on the passenger side and remove it The bearing cap must be reinstalled in its original position 11 Assemble the enclosed extrac tion tool as shown 12 Use the extraction tool to remove the tumbler and counter weight plugs A wrench may be needed to hold the tool in place 13 Remove the counterweight and tumbler assemblies from the differ ential 14 Remove the block 15 Remove the spider gears and spider gear thrust washers 16 Remove the sidegears clutch es and thrustwashers from the dif ferential 17 Reinstall the bearing cap in its original position and tighten to required torque 18 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 19 Apply wheel bearing grease to driver teeth and spacer 20 Apply wheel bearing grease to saddle springs and seat in holes 21 Install couple
6. lly i rotate both wheels backwards 1 4 turn to expose pinion shaft opening p 0 C er 3 d e e pinion shaft opening 1 7 LOS 43 Feel through pinion shaft open EN saddle springs a ing and verify both spacers and drivers are fully seated onto cou plers Verify all 8 saddle springs are fully seated in holes lt pinion shaft opening 17 44 Keeping couplers and drivers Stationary rotate case 1 4 turn for ward to align pinion shaft openings 45 Using the retaining bolt as a handle insert the shaft into the dif ferential Press hard while twisting to pass shaft by springs If excessive force is required the spacer paddle may not be aligned with the paddle opening in synchro ring Verify alignment and ensure driver spacer half block is fully seated on coupler before proceeding 46 Insert retaining bolt into case shaft Tighten retaining bolt firmly 2 18 47 Put transmission in gear or park 48 Turn driver s side wheel forward and hold against driveline for steps 49 amp 50 49 Passenger side wheel should not be able to rotate in the same direction 50 After sharply turning the passenger side wheel in the opposite direction to disen gage the unit the wheel should rotate freely 51 Repeat the test for both wheels in both directions 19 f 7 2 I
7. n 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 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 referre
8. nstall differential cover with gasket sealant 53 Add Richmond Synthetic Gear Oil 75W 140 available at your Authorized Richmond Distributor 56 Remove jack stands lower vehicle then remove blocks 20 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 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 vibratio
9. rs inside differential case thick coupler on ring gear side first 22 Install c clip on ring gear side axle shaft only 23 Make sure paddle opening widest gap in ring gear side syn chro ring is facing out towards you 24 Insert the non slotted spacer into the non slotted driver Seat the Spacer paddle at the paddle open ing in the driver missing extended tooth 25 Insert driver spacer as shown making sure spacer paddle is facing out towards you 11 0 26 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 27 Insert the slotted spacer into the slotted driver Seat the spacer pad dle at the paddle opening in the driver missing extended tooth 28 Verify paddle opening widest gap in other synchro ring is facing the back of the differential away from you toe u Sen Paddle Opening 12 29 Install slotted driver spacer mak ing sure that paddle is pointing away from you toward rear of differ ential 30 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 31 Wedge both drivers in engage ment with couplers Rotate driver s side wheel forward 1 4 turn to reveal spring slot fy alll
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