Powertrax 9201202920 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 38) .............................................. 8
Verification of Proper Assembly Test (steps 39 to 43) ....... 17
Finish Installation (steps 44 to 48) .................................. 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.
Axle Housing
Axle Shaft (2)
Ring Gear
Side Gear (2)
Differential Case
Bearing Cap (2)
Pinion Gear
Thrust Washer (2)
Pinion Shaft
Pinion Shaft
Retaining Clips (2)
2
Clutch Spring
Clutches
LIMITED SLIP DIFFERENTIAL
PART IDENTIFICATION/TERMINOLOGY
Spider Gear Washer (2)
Spider Gear (2)
Thrust Block
Pinion Shaft
Synchro
Ring
Coupler
3
Paddle
Paddle Opening
in Synchro
Driver
Saddle
Spring (8)
Active Spacer
Paddle Opening in Driver
(Missing Extended Tooth)
EXPLODED VIEW
Inner
Spring (2)
Outer
Spring (2)
Check
Block
Half Block
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. Remove the axle retaining bolts
located on the inside of the brake
backing plates. Pull out both axle
shafts approximately 8”.
8. Expose pinion shaft;remove
retaining clips and shaft.
9. Remove clutch spring (some may
have multiple coil springs) if present.
6
10. Remove both spider gears and
their thrust washers.
11. Remove side gears, clutches,
thrust washers, and thrust block.
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