Powertrax 1540 - Manual (Page 16)

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8. Place the other side gear (the one that formerly was
in the bottom of the case) onto the top driver with the teeth
meshed and then place the second thrust washer on it (Figure
12). The smoothest side of the washer is placed next to the gear.
9. Place the case cap onto the case in its marked rota-
tional position. Line up the holes and install the bolts. Torque
them to their proper value.
10. Install the ring gear in its proper marked rotational
position and then tighten the bolts.
11. Inspect your work. Look for anything that is not
correct. Reach in through each end with two fingers into the
splines and be sure that the gears and drivers rotate back and
forth smoothly, stopping at the pinion shafts.
Third Member Final Assembly
1. Position the carrier vertically, with the drive shaft
flange pointing down. It can be held in a vise or even stood on its
nose in a coffee can if a vise is not available.
2. Place the bearing races on the differential case bear-
ings. Be sure to place the marked one on the proper end.
3. Set the differential case (and bearing races) into the
carrier. Install it with ring gear pushed all the way into the drive
pinion—that is, with no backlash, and with the bearing races
pushed all the way onto the bearings.
4. Check the punch marks on the adjusters and deter-
mine which one goes on the side nearest the ring gear. Hold it
so that the mark is at its final position (where the lock will be
installed, pointing away from the carrier). Push the adjuster
against the race and slide it down into the threads in the carrier.
They should mesh easily, with no space between the parts.