Powertrax 9201202900 User Manual

INSTALLATION GUIDE

TM

Installation Guide

Contents Page

Open Differential Part Identification & 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) ......... 7

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.

Axle Housing

Axle Shaft (2)

Ring Gear

Side Gear (2)

Differential Case

Bearing Cap (2)

Pinion Gear

Thrust Washer (2)

Pinion Shaft

Roll Pin

2

Yoke

OPEN DIFFERENTIAL

PA RT IDENTIFICATION/TERMINOLOGY

Spider Gear (2)

Spider Gear Washer (2)

Thrust Block

Pinion Shaft

Synchro

Ring

Coupler

3

Paddle

Paddle Opening

in Synchro

Driver

Active Spacer

Paddle Opening in Driver
(Missing Extended Tooth)

Inner Springs (2)

Outer Springs (2)

EXPLODED VIEW

Check Block

Saddle Springs (8)

4

1. Put transmission in gear (or park), and

turn off engine.

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.

5

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.

6

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.