Powertrax no-slip installation guide
Contents
1. INSTALLATION GUIDE Ge No Slip Traction System 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 201 8 Verification of Proper Assembly Test steps 40 to 44 17 Finish Installation steps 45 to 49 0 eee eee terete eee 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 IDENTIFICATIONTERMNOLOGY Spider Gear Washer 2 Spider Gear 2 Ring Gear C Clip 2 Axle Housing Thrust Washer 2 Axle Shaft 2 Differential Case Pinion Shaft Pinion Gear Pinion Shaft Retaining Bolt or Roll Pin 2 EX PLO D ED Vi EW Check Block Paddle Opening Saddle Springs 8 in Synchro Paddle Inner Springs 2 Synchro Ring Active Spacer Non Slotted Driver Slotted Driver Non Slotted Paddle Opening in Driver Missing Extended Tooth e Active Spacer POWERTRAX pacer Coupler Slotted No Slip Traction System 1 Put transmission in gear or park and turn off en2. er spacer as shown making sure spacer paddle is facing out towards you 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 slotted spacer into the slotted driver Seat the spacer paddle at the paddle opening in driver missing 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 making sure that paddle is pointing away from you toward rear of dif ferential 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 driver s side wheel forward 1 4 turn to reveal spring slot 25 Place the two inner springs inside the two outer springs 26 Compress inner spring and install spring assembly into spring dot by 27 Visually inspect notches in spring slot to make sure inner spring is fully seated lt _ check spring key 12 28 Keeping both drivers wedged in engagement with couplers rotate driver s side wheel for
3. gine 2 Set parking brake 3 Safeguard the vehicle from rolling 4 Safely raise vehicle and apply jack stands 5 Put transmission in neutral and release parking brake 6 Remove Differential cover and drain fluid Clean the diff cover and housing sealing surface 7 Expose pinion shaft remove MIN retaining bolt roll pin and shaft 8 Push both axles inward and remove both c clips Remove o El 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 10 Pull passenger side axle shaft out approximately 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 differen tial 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 N chro ring is facing out towards you N Iz Paddle Opening 17 Insert the non slotted spacer into the non slotted driver Seat the spacer paddle at the paddle opening in driver missing extended tooth 18 Insert driv
4. springs are fully seated in holes saddle springs 15 pinion shaft opening 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 roll pin as a handle insert the shaft into the differential Press hard while twist ing to pass shaft by springs 39 Insert retaining bolt roll pin 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 Passenger side wheel should rotate freely in oppo site direction 44 Repeat the test for both wheels in both directions 17 A8 Install differential cover with gasket sealant 46 Add differential fluid 47 Set parking brake 48 Be sure transmission is in gear or park 49 Remove jack stands lower vehicle then remove blocks 18 822 1002 A Open Differential Integral Carrier C Clip Version 245 Fischer Ave Bldg B4 Costa Mesa California 92626 800 578 1020 www powertrax com 1999 Vehicular Technologies and its licensors All Rights Reserved
5. ward 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 Be S spring slot to make sure inner S 4 spring is fully seated J H N check spring k 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 driver gap is incorrect STOP and call Powertrax Technical Support at 800 578 1020 There may be a problem with your differential case 32 Push passenger side axle shaft inward through coupler as far as it will go hides oes J BD c clip wae J r slot 14 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 axle 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 open ing 36 Feel through pinion shaft open ing and verify both spacers and drivers are fully seated onto cou plers Verify all 8 saddle
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