Installing A Powertrax Differential Unit - Making Trax

The side gears and their thrust washers are the last things out of the stock differential. With the differential now stripped, the Powertrax can go in its place.

For the syncros to line up, the Powertrax components fit together in just one orientation. We marked the couplers and driver halves with a marker in the correct orientation so we could visually confirm that the pieces are correctly installed. The couplers slide in place of the side gears and use no thrust washers in this application. The C-clip on the left-side axle is now installed. The driver half is fitted with springs and the spacer, and is then slipped in to engage the coupler. If the all parts are oriented as specified in the instructions, the teeth of the driver and coupler will seat together.

Next, the four spring assemblies that fit between the halves of the Powertrax are put into position.

To make sure the clearance between the halves of the differential is within specs, the Powertrax comes with a simple gauge. This will confirm the assembly is correct; however, the unit is not adjustable.

With everything checking out OK, the right axleshaft is pushed back in, and the C-clip is installed through the window in the Powertrax. Pull the axle back outward to make sure the C-clip is properly seated.

The last step is to reinstall the pinion shaft, which has to wiggle in to get past the four springs in the pin bore. Use the lock bolt as a handle to work the shaft in, and then lock it down.

Button it back up with the cover, fill it with lube, and it's a done deal. We prefer quality silicone to a gasket here. The Powertrax requires no special lube or additive. Get the tires back on it, and it's huntin' season on Main Street.