- (10) Allen Head Bolts, M8-1.25x40
- (10) Washer, Flat M8
- (10) Washers, Lock M8
- (10) Nut, Hex, M8-1.25 CL10
- (1) Bolt, 25mm, M8
- (1) Bolt, 30mm, M8
- (1) Ultra Grey® Silicon
- (1) Instructions
- Blue LocTite® (optional)
- 5mm Allen Wrench
Preparing the Axle:
Start by removing the axles from the housing. Remove the 10 nuts holding the differential in place. Slide the differential out of the housing. Remove all 10 studs from the housing. Clean off all remains of the previous differential gasket. For ease of installation, we recommend chasing all threads before continuing.
- 1. Place one flat washer onto each new bolt.
Thread each bolt in from the inside of the housing.
Blue LocTite® can be used if desired. Tighten
studs with a 5mm allen wrench. NOTE: If you are
using a Rock Assault™ Housing, see Step 2.
- 2. If you are using a Trail-Gear housing, you will
need to use the included 25mm and 30mm bolts in
the bottom two holes of the housing. These bolts
should be inserted from the outside, into the housing.
The 30mm bolt goes into the hole located
within the raised surface (green) while the 25mm
bolt is inserted into the remaining hole (red).
- 3. Once all 10 Studs have been installed, spread a thin layer of Ultra Grey® silicone over the face of the 3rd member. Slide the 3rd member back into position on the housing. Place a lock washer and nut on each stud. Tighten nuts in a star pattern.
4. Reinstall axles into the housing and fill the differential with gear lube. Recheck nuts after the first trail run.
These instructions are designed as a general installation guide. Installation of many Trail-Gear Products require specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at (559) 252-4950 or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures.
Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Trail-Gear Inc are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use.
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