Powertrax 9220881005 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 10) ........... 5
Preparation of Parts to be Installed (steps 11 to 13) ......... 7
Assembly (steps 14 to 39) .............................................. 8
Verification of Proper Assembly Test (steps 40 to 44) ....... 17
Finish Installation (steps 45 to 49) .................................. 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
Spider Gear (2)
Pinion Shaft
Retaining Bolt
C-Clip (2)
2
Spider Gear Washer (2)
Yoke
OPEN DIFFERENTIAL
PA RT IDENTIFICATION/TERMINOLOGY
Thrust Block
Pinion Shaft
Driver
(Slotted)
Synchro
Ring
Coupler
Paddle
Paddle Opening
in Synchro
Driver
(Non-Slotted)
Saddle Springs (8)
Active Spacer
(Non-Slotted)
Paddle Opening in Driver
(Missing Extended Tooth)
Active Spacer
(Slotted)
Inner Springs (2)
Outer Springs (2)
EXPLODED VIEW
Thrust Slug
Check Block
3
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.
8. Push both axles inward and
remove both c-clips. Remove orings from c-clip grooves on axle
shafts if present.
Note: It may be necessary
to remove wheels and disc
brake calipers.
7. Expose pinion shaft;remove
retaining bolt and shaft. Remove
thrust block.
Thrust Block
6
9. Remove both spider gears and
their thrust washers.
10. Pull axle shafts out approxi-
mately 6”. Remove side gears and
thrust washers.
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