Powertrax No-Slip install tips

[batman]

The Powertrax No-Slip: installation tips for the Tundra

Just installed the No-Slip unit from Powertrax this week. Thought I would share a few things so that anyone interested would better understand what they are in for. I’ll post a review later on when I have some miles and off-road experience with it.

Here is an equipment list so that you can make sure you have what you need.
In the order you’ll need them….

Jack and lug wrench (tire removal)
Axle stands (be safe!! Make sure the truck is good and secure!!)
Pliers for the E-brake cotter pin
10mm wrench (brake line)
Pans for draining oil
Rags – lots and lots of rags!!!
Grease pencil or other labeling/marking method
Metric socket set. The 3 sized sockets you will use are 14mm, 17mm (later), 24mm.
6 pt sockets are best and a variety of extensions and ratchets are helpful. A long handled ratchet is nice to break some of the bolts loose.
Small piece of rope to tie off the drive shaft.
Some muscles or better yet two people!
Vise (4+in is best)
Drill and 1/4 inch bit
Allen wrench (5mm I think) and hammer
Wheel bearing grease
Powertrax No-Slip unit
Rubber mallet (helpful)
Torque wrench
Lock tight compound
RTV gasket compound
4 quarts of gear oil
Some fresh brake fluid
5-8 hours depending on how fast you work.

As you can see there is not much need in the way of materials/tools. Make sure you find out what the correct torque requirements are for the various nuts and bolts before you start. The bolts in the 3rd members (like ring gear bolts) are not listed in my manual so I had to guess. Save your self the aggravation look them up before you start.

Air tools would make the process faster, but are not a requirement.

The process if actually fairly easy. Follow the pictorial guide at http://www.toy4x4.net/rear_locker/index.htm This was VERY helpful for me . Everything was very similar except the part about reusing the thrust washers. With the No-Slip unit you DO NOT reuse them. Also when removing the cross shaft (pinion shaft) pin, after drilling the case, an Allen wrench works great to push the pin out.

Take careful notes on which way things go back together and make where things line up (like the bearing cap, ring gear and drive shaft). As Mike says be very careful to keep the shims separate and labeled. Best that everything goes back exactly how it came off so you don’t throw anything off balance.

OK, now when installing the actual no-slip parts they only go in one way. Take some time to look at and play with the way the driver – active spacer – coupler all go together (see the powertrax manual for all terminology). How the driver and spacer go together is fairly obvious, but the is also a spot on the coupler where the paddle of the spacer goes into (the “paddle opening in synchro”). They all need to be lined up when sliding the driver (with the spacer) into the case. IMPORTANT: Now when installing the pinion shaft it will take some effort to get it to go through the differential case. We used a hammer with a LIGHT tapping motion. There should be little to NO resistance from the internal powertrax parts. If the pinion shaft does not go in easily or stops when it contacts the drivers stop immediately! Take it all apart, something is NOT lined up correctly.

I also will repeat Mike’s comment about putting the ring gear in the sun to warm it up. Mine went on fairly easily with tapping from a rubber mallet. Once on a little we used 4 of the ring gear bolts to snug up the ring gear.

The reinstall process is fast but that 3rd member weighs a ton – especially when you are lying on your side under the truck!!

Time Line:

This job took two people about 6-7 hours (at a leisurely pace).
0.5 hrs to rack up the truck and get it safe to work on.
1.5 hrs to get the brakes off, axles out, and 3rd member off.
1.5 hrs to disassemble the 3rd member
0.5 hrs to put the powertrax parts in
0.5 hrs to put the powertrax parts in the second time
0.5 hrs to reassemble the 3rd member
1.0 hrs to reassemble the truck.
1.0 hrs worth of breaks and Internet checks at TS.

I’ll post driving impressions later after I get some miles on it!
Hope this helps, contact me if you have specific questions.

TIM