Powertrax 1540 - Manual (Page 17)

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5. Install the correctly-marked cap. Use the bolts as
guides by turning them in two threads or so and then sliding the
cap down to meet the case. Be sure that the cap threads fit into
those in the adjuster. Do not force anything. the cap should slide
down very close to the carrier surface. Tighten the bolts until
they are snug (see Figure 2).
6. Hold the other adjuster so that the mark is in the
same relative position as the other one (with the mark away from
the carrier) and slide it down the bearing race into the threads.
As it meshes, it should shift outward a little and be positioned
slightly away from the race.
7. Install the other cap. Again, use the bolts as guides
by turning them in two threads or so and then sliding the cap
down to meet the case. Turn the bolts until they are barely snug.
Be sure that the cap threads fit into those in the adjuster. Do not
force anything.
8. Use a spanner wrench or a blunt punch and a ham-
mer to turn the second adjuster (the one away from the ring gear)
one turn inward (clockwise) until the marked hole reaches its fi-
nal position (in the middle of the cap just below the lock). The
last portion of the turn should be difficult because pre-load is
being applied to the bearings by spreading the caps apart as the
adjuster is being turned in.
9. Insert an axle shaft or bar into one of the axle shaft
holes in the differential case to help with holding the assembly or
place it in a large vise, and torque the cap bolts to their correct
value (see the shop manual).
10. Install the adjuster locks and torque the bolts. Be
sure that they are located in the marked holes (as shown in Fig-
ure 2).
Assembly Inspection
1. Inspect your work. Look for anything that is not cor-
rect. Be sure that the drivers rotate back and forth smoothly,
stopping at the pinion shaft. Use a light to see that the spacers