AE Nitro TC3 RTR User manual

AE
Brand
AE
Model
Nitro TC3 RTR
Type
User manual
T E A M N T C 3 K I T
KIT INCLUDES:
Threaded shocks.
2-speed Transmission.
Pro-Line wheels & tires.
Aluminum MIP CVD's.
Associated steel turnbuckles.
Also includes:
6061 T6 aluminum chassis.
Precision rubber-sealed ball
bearings.
Tuned pipe and manifold.
Thank you for purchasing this
Team Associated product.
This manual contains steps
and instructions you will use
to set up your car. Please
read this entire manual before
attempting to start your car.
Follow the directions in this
manual closely to reduce any
problems on start up. We
hope that you will enjoy your
new Team Asssociated car.
2
YOU WILL NEED THESE TOOLS
TO ASSEMBLE YOUR KIT
Phillips screwdriver #2.
1/8" flat head screwdriver.
5/16" driver or glow plug wrench.
Needlenose pliers.
Thread locking compound (#1596
Locking Adhesive or equivalent)
Super glue or tire adhesive
(#1597).
Hobby knife
WARNING!
This knife
cuts plastic and fingers with equal
ease, so be careful.
Precision ruler.
YOUR ENGINE MAY REQUIRE
TOOLS NOT LISTED HERE.
WARNING! Always
use hand and eye
protection with cyano-
acrylic glue!
R E Q U I R E D E Q U I P M E N T T O R U N Y O U R K I T
WARNING!
Do not use a power
screwdriver to install screws
into nylon, plastic, or
composite materials. The
fast rotation speed can heat
up the screws being
installed. They can break
the molded parts or strip the
threads during installation.
for the
pull start
version of
Team Kit #2030:
Glow plug starter.
Model car fuel.
Fuel bottle.
Receiver battery pack.
Glow plugs (AE #MC-59).
R/C two channel surface
frequency radio system
with two servos.
.12 or .15 c.i. glow fuel R/C
engine.
200mm touring car body.
for the
non pull start
version of
Team Kit #2031
Glow plug starter.
Model car fuel.
Fuel bottle.
Receiver battery pack.
Glow plugs (AE #MC-59).
Starter box or electric hand starter
with car starter donut
12 volt battery for starter system.
R/C two channel surface
frequency radio system
with two servos.
.12 or .15 c.i. glow fuel R/C engine
.
200mm touring car body.
TOOLS SUPPLIED
Allen wrenches (#6950)
, .050", 1/16", 3/32", 5/64"
Clutch nut wrench (#1721)
Molded tools (#6956):
Droop gauge (#3987)
Camber/toe-in gauge (#1719)
Track width/ride height tool (#1719)
0
1
2
3
4
5
6
7
8
Log on to www.rc10.com and get your FREE computer wallpaper!
S W I N G R A C K A S S E M B L Y
A t t a c h t w o # 3 8 5 7 s h o r t b a l l e n d s t o t h e # 2 2 2 8
s w i n g r a c k a n d o n e t o t h e # 2 2 2 8 s w i n g r a c k a r m .
S l i d e t h e # 3 9 2 9 s p r i n g a n d # 2 2 2 8 r a c k s h i m o n t o
t h e # 6 9 1 8 s c r e w . S l i d e t h e s c r e w a s s e m b l y
t h r o u g h t h e b o t t o m o f t h e s w i n g r a c k .
A t t a c h t h e # 2 2 2 8 s w i n g r a c k a r m t o t h e s w i n g
r a c k w i t h a # 4 4 4 9 l o c k n u t .
T i g h t e n d o w n t h e s c r e w u n t i l t h e s c r e w e n d i s
e v e n w i t h t h e t o p o f t h e n u t .
B A G A
R E M O V E T H E S E
P A R T S F O R :
S t e p 1
1 : 1
R E A D T H I S B E F O R E B U I L D I N G
R E A D T H E M A N U A L !
T h i s m a n u a l i s f o r t w o d i f f e r e n t N T C 3 k i t s a n d w i l l h e l p y o u
a s s e m b l e a n d s e t u p e a c h o n e . R e a d t h e m a n u a l b e f o r e
s t a r t i n g y o u r k i t a n d b e f o r e c o n t a c t i n g u s f o r h e l p . " H e l l o ,
A s s o c i a t e d , I n e e d s o m e h e l p . " " D i d y o u r e a d t h e m a n u a l ? "
O P E N T H E B A G S I N O R D E R
T h e a s s e m b l y i s a r r a n g e d s o t h a t y o u w i l l o p e n a n d f i n i s h
t h a t b a g b e f o r e y o u g o o n t o t h e n e x t b a g .
S o m e t i m e s y o u
w i l l h a v e p a r t s r e m a i n i n g a t t h e e n d o f a b a g . T h e s e w i l l
b e c o m e p a r t o f t h e n e x t b a g .
S o m e b a g s m a y h a v e a l a r g e
a m o u n t o f s m a l l p a r t s . T o m a k e i t e a s i e r t o f i n d t h e p a r t s , w e
r e c o m m e n d u s i n g a p a r t i t i o n e d p a p e r p l a t e f o r s p r e a d i n g o u t
t h e p a r t s s o t h e y w i l l b e e a s i e r t o f i n d .
S U P P L E M E N T A L S H E E T S
W e a r e c o n s t a n t l y u p d a t i n g p a r t s t o i m p r o v e o u r k i t s . T h e s e
c h a n g e s , i f a n y , w i l l b e n o t e d i n s u p p l e m e n t a r y s h e e t s
l o c a t e d i n a p a r t s b a g o r i n s i d e t h e k i t b o x . C h e c k t h e k i t b o x
b e f o r e y o u s t a r t a n d e a c h b a g a s i t i s o p e n e d . W h e n a
s u p p l e m e n t i s f o u n d , a t t a c h i t t o t h e a p p r o p r i a t e s e c t i o n o f
t h e m a n u a l .
M A N U A L F O R M A T
T h e f o l l o w i n g e x p l a i n s t h e f o r m a t o f t h e s e i n s t r u c t i o n s .
T h e b e g i n n i n g o f e a c h s e c t i o n i n d i c a t e s :
1
W h i c h b a g t o o p e n
( " B A G A " )
a n d w h i c h s t e p s y o u ' l l b e
u s i n g t h o s e p a r t s f o r
( " F O R S T E P S 1 - 3 " ) .
2
W h i c h p a r t s y o u w i l l u s e f o r t h o s e s t e p s . R e m o v e o n l y t h e
p a r t s s h o w n .
" 1 : 1 "
i n d i c a t e s a n a c t u a l s i z e d r a w i n g ; p l a c e
y o u r p a r t o n t o p o f t h e d r a w i n g a n d c o m p a r e i t s o i t d o e s n o t
g e t c o n f u s e d w i t h a s i m i l a r p a r t .
3
W h i c h t o o l s y o u s h o u l d h a v e h a n d y f o r t h a t s e c t i o n .
4
T h e i n s t r u c t i o n s i n e a c h s t e p a r e o r d e r e d i n t h e o r d e r y o u
c o m p l e t e t h e m , s o r e a d t h e w o r d s A N D f o l l o w t h e p i c t u r e s .
T h e n u m b e r s i n c i r c l e s a r e a l s o i n t h e d r a w i n g t o h e l p y o u
l o c a t e t h e m f a s t e r .
5
W h e n w e r e f e r t o l e f t a n d r i g h t s i d e s o f t h e c a r , w e a r e
r e f e r r i n g t o t h e d r i v e r ' s p o i n t o f v i e w i n s i d e t h e c a r .
6
Y o u ' l l s e e a c a r a n g l e d i n a p a r t i c u l a r d i r e c t i o n i n s e v e r a l
s t e p s . T h e a n g l e s h o w s y o u w h i c h w a y t h e p a r t i s b e i n g
v i e w e d , h e l p i n g y o u t o t e l l f r o n t a n d r e a r , l e f t a n d r i g h t .
R E A C H I N G U S
A S S O C I A T E D E L E C T R I C S , I N C .
3 5 8 5 C a d i l l a c A v e .
C o s t a M e s a , C A 9 2 6 2 6 - 1 4 0 1
U S A
© 2 0 0 1 A s s o c i a t e d E l e c t r i c s , I n c .
C U S T O M E R S U P P O R T
( 7 1 4 ) 8 5 0 - 9 3 4 2 , e x t . 6 2 4
F A X ( 7 1 4 ) 8 5 0 - 1 7 4 4
w e b s i t e : h t t p : / / w w w . r c 1 0 . c o m /
3
M a t c h t h i s n u m b e r
t o t h e t e x t t o f i n d
y o u r w a y f a s t e r
s t e p 1
3 9 2 9 , q t y 1
s p r i n g
6 9 1 8 , q t y 1
4 - 4 0 x 1 / 2 " s c r e w
2 2 2 8 , q t y 1
s w i n g r a c k
4 4 4 9 , q t y 1
4 - 4 0 l o c k n u t
2 2 2 8 , q t y 1
s w i n g r a c k a r m
3 8 5 7
2 2 2 8
s w i n g r a c k a r m
2 2 2 8
s w i n g r a c k
2 2 2 8
3 9 2 9
6 9 1 8
4 4 4 9
3 8 5 7
3 8 5 7
1 : 11 : 11 : 1
T O O L S U S E D
3 8 5 7 , q t y 3
s h o r t s p e c i a l
b a l l e n d , b l a c k
2 2 2 8 , q t y 1
. 1 2 5 x . 2 5 0 r a c k
s h i m
1 / 1 6 "
3 / 1 6 "
4
B A G A
R E M O V E T H E S E
P A R T S F O R :
S t e p s 2 - 3
T O O L S U S E D
s t e p 2
S l i d e t h e # 2 2 2 9 p i v o t p o s t t h r o u g h t h e
s w i n g r a c k f o l l o w e d b y a # 2 2 2 8 s w i n g
r a c k b e l l c r a n k a r m .
S l i d e o n e # 7 3 3 7 w a s h e r o n t o t h e # 2 2 2 9
s c r e w t h e n s l i d e t h e s c r e w t h r o u g h t h e
p i v o t p o s t . N o w t i g h t e n d o w n t h e s c r e w ,
b u t n o t t o t h e p o i n t o f d a m a g i n g t h e
t h r e a d s .
2 2 2 9 , q t y 2
p i v o t p o s t
1 : 1
s t e p 3
S W I N G R A C K T O C H A S S I S
I n s t a l l t h e t w o # 2 2 2 9 s w i n g r a c k
m o u n t i n g p o s t s t o t h e # 2 2 2 4 c h a s s i s w i t h
# 6 2 9 1 s c r e w s .
S l i d e o n e # 2 2 3 4 3 / 1 6 x 5 / 1 6 " b u s h i n g
o n t o e a c h p o s t . S l i d e t h e s w i n g r a c k
a s s e m b l y d o w n , m a k i n g s u r e t h e
m o u n t i n g p o s t s a r e i n f r o n t o f t h e r a c k .
N o w i n s e r t t h e # 2 2 3 4 1 / 8 x 1 / 4 " b u s h i n g s
i n t o t h e r a c k a s s e m b l y w h e r e s h o w n .
F a s t e n t h e s w i n g r a c k d o w n w i t h # 6 4 7 2
n y l o n l o c k n u t s . T i g h t e n d o w n e a c h n u t
u n t i l t h e s w i n g r a c k d o e s n ' t m o v e f r e e l y .
T h e n l o o s e n e a c h n u t a ¼ t u r n o r u n t i l i t
m o v e s f r e e l y .
2 2 2 8 , q t y 2
s w i n g r a c k b e l l c r a n k a r m
1 : 1
1 : 1 1 : 1
2 2 2 9 , q t y 2
s w i n g r a c k m o u n t i n g p o s t
2 2 2 9 , q t y 2
s c r e w
2 2 2 4 , q t y 1
N T C 3 c h a s s i s
7 3 3 7 , q t y 2
w a s h e r
B A G B
R E M O V E T H E S E
P A R T S F O R :
S t e p s 1 - 3
T O O L S U S E D
3 8 6 5 , q t y 4
s e t s c r e w
1 : 1
2 2 3 3 , q t y 2
f r o n t a - a r m s ,
r i g h t & l e f t
2 2 3 1 , q t y 1
f r o n t a r m r e a r
m o u n t
2 2 4 0 , q t y 8
5 - 4 0 x 7 / 1 6 s c r e w
2 2 4 2 , q t y 4
h i n g e p i n
2 2 2 9
2 2 2 8
7 3 3 7
2 2 2 9
2 2 2 9
7 3 3 7
2 2 2 9
2 2 2 8
s w i n g r a c k
2 2 2 9
2 2 3 4
6 4 7 2
2 2 2 4
6 2 9 1
6 2 9 1
s w i n g r a c k
a s s e m b l y
2 2 3 4
2 2 3 4
6 4 7 2
2 2 3 4 , q t y 2
1 / 8 x 1 / 4 b u s h i n g
6 4 7 2 , q t y 2
n y l o n l o c k n u t
1 : 11 : 1
1 : 1
2 2 4 3 , q t y 2
r e a r a - a r m s ,
r i g h t & l e f t
2 2 3 1 , q t y 1
r e a r a r m f r o n t
m o u n t
2 2 5 7 , q t y 2
b a l l e n d
1 : 1
0
1
2
3
4
5
6
7
8
6 2 9 1 , q t y 2
4 - 4 0 X 1 / 4 s c r e w
2 2 3 4 , q t y 2
3 / 1 6 x 5 / 1 6 . 1 0 9 b u s h i n g
u n f l a n g e d
1 : 1
T H R E A D L O C K
r e c o m m e n d e d
o n s c r e w s # 6 2 9 1
1 / 1 6 "
1 / 1 6 " , 5 / 6 4 " , 3 / 3 2 "
3 / 1 6 "
1 : 1
2 2 2 6 , q t y 1
f r o n t b u m p e r /
a r m m o u n t
C A R S H O W S
V I E W I N G A N G L E
P U T A S I D E T H E # 2 2 3 3 & # 2 2 4 3 U P P E R A R M S
U N T I L T H E Y A R E C A L L E D F O R I N B A G E .
3 8 6 5
2 2 3 3
2 2 3 1
2 2 4 0
2 2 4 2
2 2 2 6
2 2 3 3
2 2 4 0
2 2 4 2
2 2 4 0
2 2 4 0
3 8 6 5
F R O N T A R M A S S E M B L Y
I n s t a l l a # 3 8 6 5 s e t s c r e w i n t o e a c h o f t h e # 2 2 3 3 f r o n t a r m s ,
m a k i n g s u r e t h e r e i s a r i g h t a n d a l e f t s i d e . ( W e w i l l d o t h e f i n a l
s c r e w a d j u s t m e n t i n s t e p 3 . )
A t t a c h t h e # 2 2 3 1 f r o n t a r m , r e a r m o u n t t o t h e c h a s s i s w i t h t w o
# 2 2 4 0 s c r e w s .
S l i d e t h e # 2 2 4 2 h i n g e p i n s t h r o u g h t h e # 2 2 3 3 a r m s . S l i d e t h e
p i n s w i t h t h e a r m s i n t o t h e a r m m o u n t .
A l i g n t h e # 2 2 2 6 f r o n t b u m p e r / a r m m o u n t w i t h t h e t w o h i n g e
p i n s a n d s l i d e t o g e t h e r . T i g h t e n i t d o w n w i t h t w o # 2 2 4 0
s c r e w s .
I J A F  
R E A R A R M A S S E M B L Y
I n s t a l l a # 3 8 6 5 s e t s c r e w i n t o e a c h o f t h e # 2 2 4 3 r e a r a r m s ,
m a k i n g s u r e t h e r e i s a r i g h t a n d a l e f t s i d e . ( W e w i l l d o t h e f i n a l
s c r e w a d j u s t m e n t i n s t e p 3 . )
A t t a c h # 2 2 3 1 r e a r a r m f r o n t m o u n t t o t h e c h a s s i s w i t h t w o
# 2 2 4 0 s c r e w s .
S l i d e t h e # 2 2 4 2 h i n g e p i n s t h r o u g h t h e # 2 2 4 3 r e a r a r m s . S l i d e
t h e p i n s w i t h t h e a r m s i n t o t h e # 2 2 3 1 r e a r a r m f r o n t m o u n t .
I n s t a l l t h e t w o # 2 2 5 7 b a l l e n d s i n t o t h e # 2 2 3 1 r e a r a r m m o u n t .
A l i g n t h e r e a r a r m m o u n t u p w i t h t h e t w o h i n g e p i n s a n d s l i d e
t o g e t h e r . T i g h t e n d o w n w i t h t w o # 2 2 4 0 s c r e w s .
I J A F 
3 8 6 5
2 2 5 7
( g o l d )
3 8 6 5
2 2 4 3
2 2 4 3
2 2 3 1
2 2 4 0 2 2 4 0
2 2 4 0
2 2 4 0
2 2 4 2
2 2 4 2
S E T T I N G D R O O P
P l a c e t h e s u p p l i e d # 3 9 8 7 d r o o p g a u g e o n a f l a t
s u r f a c e . P l a c e t h e b o t t o m o f t h e c h a s s i s o n t o p a s
s h o w n . M a k e s u r e t h e s c r e w s a r e n o t r e s t i n g o n t h e
g a u g e a n d t h a t y o u a r e h o l d i n g t h e c h a s s i s a n d g a u g e
f l a t .
S l i d e t h e g a u g e o u t s o t h e s h o c k m o u n t i n g p o r t i o n o f
t h e f r o n t a r m r e s t s o n s t e p 4 . W i t h y o u r 3 / 3 2 A l l e n
w r e n c h , a d j u s t t h e s e t s c r e w s o t h e o u t e r p a r t o f t h e
a r m j u s t t o u c h e s t h e s t e p . A d j u s t b o t h f r o n t a r m s .
S l i d e t h e g a u g e t o t h e r e a r a r m s a n d r e p e a t t h e
a d j u s t m e n t . T h e s h o c k m o u n t i n g p o r t i o n o f t h e
r e a r a r m s w i l l r e s t o n s t e p 3 .
I J A F  !
3 9 8 7
3 9 8 7
F R O N T A R M S R E S T O N S T E P 4
R E A R A R M S R E S T O N S T E P 3
A D J U S T
D R O O P
S C R E W
A D J U S T
D R O O P
S C R E W
5
T h i s p o i n t s t o r e a r o f c a r
F R O N T
R E A R
2 2 3 1
D I F F E R E N T I A L R I N G G E A R
T r i m a n y b u r r s f r o m t h e e d g e s s h o w n w i t h a h o b b y
k n i f e .
S l i d e a # 6 9 0 9 b e a r i n g i n t o t h e # 2 3 3 2 f r i c t i o n d i s c . S l i d e
t h e b e a r i n g a n d d i s c i n t o t h e c e n t e r o f t h e # 2 3 2 9 r i n g
g e a r .
A d d a g e n e r o u s a m o u n t o f # 6 5 9 1 dif l u b e t o t h e
# 2 3 2 9 r i n g g e a r h o l e s a n d f r i c t i o n d i s c . P u s h i n t h e
t w e l v e # 6 5 8 1 d i f f b a l l s . N o w p u s h t h e l u b e b a c k i n t h a t
c a m e o u t .
B A G C
R E M O V E T H E S E
P A R T S F O R :
S t e p s 1 - 5
s t e p 1
2 3 2 9 , q t y 2
r i n g g e a r
1:1
T O O L S U S E D
6 9 0 9
L O N G O U T D R I V E
R e m o v e a n y o i l r e s i d u e t h o r o u g h l y w h e r e s h o w n .
W i t h a p a i r o f
p l i e r s , c o m p r e s s t h e # 6 5 8 2 s p r i n g a f e w t i m e s . P u s h t h e # 6 5 8 2 d i f f
s p r i n g i n t o t h e # 2 3 2 8 l o n g o u t d r i v e .
S l i d e t h e # 2 3 3 0 T - n u t i n t o t h e l o n g o u t d r i v e .
I n s e r t o n e # 6 9 0 9 b e a r i n g i n t o t h e f a c e o f t h e l o n g o u t d r i v e .
A d d a l i g h t c o a t o f # 6 5 9 1 dif l u b e t o t h e l o n g o u t d r i v e f a c e a s
s h o w n . P l a c e a # 2 3 3 1 d r i v e r i n g o n t h e o u t d r i v e f a c e .
s t e p 2
S H O R T O U T D R I V E
R e m o v e a n y o i l r e s i d u e t h o r o u g h l y w h e r e s h o w n .
H o l d t h e
# 6 5 7 3 d i f f b o l t w i t h y o u r 5 / 6 4 " A l l e n w r e n c h a n d s l i d e o n e # 6 5 7 3
t h r u s t w a s h e r o n t o t h e # 6 5 7 3 d i f f b o l t .
A p p l y a g e n e r o u s a m o u n t o f # 6 5 8 8 b l a c k g r e a s e t o t h e w a s h e r o n
t h e s i d e f a c i n g a w a y f r o m t h e b o l t h e a d .
P l a c e s i x # 6 5 7 4 b a l l s i n t o t h e g r e a s e a g a i n s t t h e # 6 5 7 3 b o l t a n d
w a s h e r . A d d t h e s e c o n d # 6 5 7 3 w a s h e r . T h e g r e a s e w i l l h o l d t h e
b a l l s i n p l a c e d u r i n g a s s e m b l y , s a n d w i c h i n g t h e b a l l s a n d w a s h e r s .
S l i d e t h e t h r u s t a s s e m b l y i n t o t h e # 2 3 2 8 s h o r t o u t d r i v e , b e i n g
c a r e f u l n o t l o s e a n y o f t h e b a l l s .
A d d a l i g h t c o a t o f # 6 5 9 1 l u b e t o t h e s h o r t o u t d r i v e f a c e a s
s h o w n .
P l a c e a # 2 3 3 1 d r i v e r i n g a n d t h e n t h e g e a r a s s e m b l y o n t h e
o u t d r i v e .
s t e p 3
6 5 9 1 , q t y 1
Tranny l u b e
6
2 3 3 2
2 3 2 9
6 5 9 1
6 5 8 1
6 5 8 2
T r i m a n y b u r r s f r o m t h e s e
e d g e s w i t h a h o b b y k n i f e .
6 9 0 9 , q t y 4
3 / 1 6 x 5 / 1 6 b e a r i n g
u n f l a n g e d
1:1
2 3 3 2 , q t y 2
f r i c t i o n d i s c
1:1
6 5 8 1 , q t y 2 4
d i f f b a l l s
6 5 8 2 , q t y 2
d i f f s p r i n g
2 3 2 8 , q t y 2
l o n g o u t d r i v e
2 3 3 0 , q t y 2
T - n u t
1 : 1
6 5 7 3 , q t y 4
t h r u s t w a s h e r
1 : 1
6 5 7 5 , q t y 2
d i f f b o l t
6 5 8 8 , q t y 1
b l a c k g r e a s e
1 : 1
6 5 7 4 , q t y 1 2
t h r u s t b a l l s
2 3 2 8 , q t y 2
s h o r t o u t d r i v e
2 3 3 1 , q t y 4
d r i v e r i n g
2 2 9 3 , q t y 4
o u t d r i v e s h i m
5 / 6 4 "
3 9 7 6 , q t y 4
3 / 8 x 5 / 8 b e a r i n g
r u b b e r s e a l e d , u n f l a n g e d
1 : 1
1 : 1
1 : 1
2 3 2 8
2 3 3 0
6 9 0 9
6 5 9 1
6 5 7 3
6 5 7 3
6 5 8 8
6 5 7 4
6 5 7 3
2 3 2 8
6 5 9 1
2 3 3 1
g e a r a s s e m b l y
2 3 3 1
5 / 6 4 " A l l e n w r e n c h
r e m o v e a n y o i l r e s i d u e t h o r o u g h l y
b e f o r e a p p l y i n g S t e a l t h l u b e
r e m o v e a n y o i l r e s i d u e t h o r o u g h l y
b e f o r e a p p l y i n g
0 F u l l y t i g h t e n e d p o s i t i o n
- 1 / 8
- 1 / 4
- 3 / 8
- 5 / 8
- 3 / 4
- 1 / 2
S t a n d a r d s e t t i n g
f o r F R O N T D I F F
S t a n d a r d s e t t i n g
f o r R E A R D I F F
5 / 6 4 " A l l e n
w r e n c h
i n s t a l l e d i n
d i f f b o l t
2 2 9 3
2 2 9 3
3 9 7 6
3 9 7 6
2 2 7 0
6 9 2 0
2 2 9 1
3 9 7 7
7
P l a c e o n e # 2 2 9 3
o u t d r i v e s h i m o n b o t h
t h e l o n g a n d s h o r t
o u t d r i v e s .
P l a c e o n e # 3 9 7 6
b e a r i n g o v e r e a c h
o u t d r i v e .
s t e p 5
B A G C
R E M O V E T H E S E
P A R T S F O R :
S t e p 6
T O O L S U S E D
3 9 0 3 , q t y 1
d r i v e p i n i o n
s t e p 6
F R O N T I N P U T S H A F T A S S E M B L Y
I n s t a l l a n d c e n t e r t h e # 2 2 9 1 d o w e l p i n i n t o t h e # 3 9 2 0 f r o n t
i n p u t s h a f t .
T r i m b u r r s f r o m t h e d r i v e p i n i o n e d g e w h e r e s h o w n a b o v e .
S l i d e t h e # 3 9 0 3 d r i v e p i n i o n o n t o t h e i n p u t s h a f t .
M a k e
s u r e t h e d o w e l p i n a l i g n s p e r f e c t l y w i t h t h e s l o t i n t h e
p i n i o n .
A d d t h e # 6 2 9 9 s m a l l E - c l i p .
S l i d e t w o # 2 2 9 3 i n p u t s h a f t s h i m s a n d o n e # 3 9 7 7 b e a r i n g
o n t o t h e # 3 9 2 0 i n p u t s h a f t .
2 2 9 3
2 2 9 3 , q t y 3
i n p u t s h a f t
s h i m
1 : 1
6 2 9 9 , q t y 1
s m a l l E - c l i p
3 9 2 0 , q t y 1
f r o n t i n p u t s h a f t
3 9 7 7 , q t y 2
3 / 1 6 x 3 / 8 b e a r i n g ,
r u b b e r s e a l e d
2 2 7 0 , q t y 1
d r i v e c u p
6 9 2 0 , q t y 1
4 - 4 0 x 3 / 1 6 s c r e w
2 2 9 1 , q t y 2
d o w e l p i n
3 9 2 0
2 2 9 1
3 9 0 3
6 2 9 9
1 / 1 6 "
S l i d e t h e s e c o n d # 3 9 7 7 b e a r i n g o n t o
t h e i n p u t s h a f t , f o l l o w e d b y t h e t h i r d
# 2 2 9 3 i n p u t s h a f t s h i m .
I n s t a l l a n d c e n t e r t h e # 2 2 9 1 d o w e l p i n
i n t o t h e i n p u t s h a f t .
S l i d e a # 2 2 7 0 d r i v e c u p o n t o t h e e n d o f
t h e i n p u t s h a f t .
T i g h t e n i t d o w n w i t h o n e # 6 9 2 0 s c r e w .
f r o n t i n p u t s h a f t
a s s e m b l e d
P L E A S E C O M P A R E
Y O U R A S S E M B L Y
C A R E F U L L Y
1 : 11 : 1
T r i m a n y b u r r s f r o m t h i s
e d g e o f t h e d r i v e p i n i o n
w i t h a h o b b y k n i f e .
1 : 1 1 : 1
3 9 7 7
s t e p 4
H o l d i n g t h e s h o r t o u t d r i v e a s s e m b l y s t i l l
w i t h y o u r 5 / 6 4 " A l l e n w r e n c h , p l a c e t h e
l o n g o u t d r i v e a s s e m b l y i n t o t h e f a c e o f
t h e s h o r t o u t d r i v e / g e a r a s s e m b l y .
C H E C K T H E A L I G N M E N T
T i g h t e n t h e d i f f t o g e t h e r w i t h y o u r 5 / 6 4 A l l e n
w r e n c h , b u t n o t c o m p l e t e l y .
N O T E :
Y o u m a y n e e d t o h o l d t h e T - n u t i n
p l a c e w h e n a s s e m b l i n g t h e t w o o u t d r i v e s .
R o t a t e t h e d i f f h u b s s e v e r a l t i m e s a s y o u a r e
t i g h t e n i n g t h e b o l t t o c h e c k p r o p e r a l i g n m e n t
o f t h e p a r t s . R E A D S T E P 4 C A R E F U L L Y .
A D J U S T T H E D I F F
A s y o u t i g h t e n t h e d i f f
b o l t , y o u w i l l n o t i c e t h e
T - n u t e a r s m o v i n g
c l o s e r t o t h e b o t t o m o f
t h e o u t d r i v e s l o t . T h i s
c o m p r e s s e s t h e s p r i n g b e h i n d t h e T -
n u t . T h e s p r i n g s h o u l d b e f u l l y c o m p r e s s e d a t
t h e s a m e t i m e t h e T - n u t r e a c h e s t h e e n d o f t h e
s l o t .
C A U T I O N :
P a y c l o s e a t t e n t i o n t o t h e f e e l i n g w h e n
t h e s p r i n g i s f u l l y c o m p r e s s e d . D o n o t o v e r t i g h t e n t h e b o l t .
W h e n y o u f e e l t h e s p r i n g f u l l y c o m p r e s s e d , l o o s e n t h e d i f f b o l t
1 / 4 o f a t u r n f o r t h e f r o n t a n d 1 / 2 o f a t u r n f o r t h e r e a r . Y o u r d i f f
s h o u l d n o w o p e r a t e v e r y s m o o t h l y w i t h t h e o u t d r i v e s m o v i n g i n
o p p o s i t e d i r e c t i o n s . A f t e r y o u h a v e d r i v e n t h e c a r o n c e , r e c h e c k
t h e d i f f a d j u s t m e n t .
N o w a s s e m b l e t h e s e c o n d d i f f t h e s a m e w a y .
2
3
4
5
- 1 / 8 - 1 / 4 - 3 / 8 - 1 / 2 - 5 / 8 - 3 / 4
R e s u l t
D i f f T i g h t e r D i f f L o o s e r
F R O N T D I F F
L e s s S t e e r i n g M o r e S t e e r i n g
R E A R D I F F
M o r e S t e e r i n g L e s s S t e e r i n g
C A U T I O N : D o n o t t u r n t h e d i f f b o l t o u t m o r e t h a n 3 / 4 o f a t u r n .
A m o u n t t h e d i f f b o l t i s t u r n e d o u t f r o m t i g h t p o s i t i o n ( c o u n t e r c l o c k w i s e )
O n c e y o u h a v e f u l l y t i g h t e n e d t h e d i f f b o l t a n d s p r i n g ,
u s e t h e c h a r t a t r i g h t t o f i n e t u n e y o u r N T C 3 s e t t i n g s .
2 2 9 3
2 2 8 7 , q t y 1
t w o s p e e d h o u s i n g
2 2 6 6 , q t y 1
5 4 T s p u r g e a r
2 2 8 8 , q t y 1
o n e - w a y h u b
2 6 6 1 , q t y 1
l a r g e E - c l i p
2 2 6 4 , q t y 1
5 0 T s p u r g e a r
6 9 2 0 , q t y 6
4 - 4 0 x 3 / 1 6 s c r e w
1 : 1 1 : 1
s t e p 9
A t t a c h # 2 2 6 4 5 0 t o o t h ( s m a l l e r ) s p u r
g e a r t o # 2 2 8 7 t w o s p e e d h o u s i n g w i t h
t h r e e # 6 9 2 0 s c r e w s .
S l i d e t h e h o u s i n g o n t o t h e r e a r i n p u t
s h a f t , m a k i n g s u r e t h a t t h e h o u s i n g
c o v e r s t h e c l u t c h s h o e s .
s t e p 1 0
A t t a c h # 2 2 6 6 5 4 t o o t h ( l a r g e r ) s p u r g e a r t o t h e
# 2 2 8 8 o n e - w a y h u b w i t h t h r e e # 6 9 2 0 s c r e w s .
S l i d e t h e o n e - w a y h u b o n t o t h e i n p u t s h a f t .
N o w p u s h # 2 6 6 1 e - c l i p i n t o p l a c e .
2 2 6 4 ( 5 0 T )
2 2 8 7
6 9 2 0
6 9 2 0
6 9 2 0
s l i d e b e l l o v e r
c l u t c h s h o e s
2 2 6 6 ( 5 4 T )
2 2 8 8
2 6 6 1
6 9 2 0
6 9 2 0
6 9 2 0
B A G C
R E M O V E T H E S E
P A R T S F O R :
S t e p s 7 - 1 0
T O O L S U S E D
2 2 8 9 , q t y 2
8 - 3 6 s e t s c r e w
( s i l v e r )
6 5 9 1 , q t y 1
S t e a l t h l u b e
2 2 8 9 , q t y 2
1 / 8 " b a l l
2 2 8 9 , q t y 2
a d j u s t m e n t s p r i n g
2 2 8 9 , q t y 2
a d j u s t m e n t s c r e w
2 - 5 6 x 9 / 1 6
2 2 9 2 , q t y 2
t w o s p e e d s h o e
2 2 8 6 , q t y 1
i n p u t s h a f t
1 : 1 1 : 1 1 : 1
s t e p 7
T W O S P E E D S H O E S
D e b u r r h o l e s e d g e s o n # 2 2 9 2 t w o s p e e d s h o e s
a s s h o w n .
I n s t a l l # 2 2 8 9 s e t s c r e w s i n t o t h e t w o s p e e d
s h o e s u n t i l t h e s e t s c r e w s a r e f l u s h w i t h t h e
o u t e r p a r t o f t h e s h o e s .
A d d a d a b o f # 6 5 9 1 l u b e t o t h e # 2 2 8 9
b a l l a n d i n s e r t i t i n t o t h e h o l e , r e s t i n g a g a i n s t t h e
e n d o f t h e s e t s c r e w . S c r e w i n t h e s e t s c r e w
u n t i l t h e b a l l i s s l i g h t l y a b o v e t h e f l a t s u r f a c e o n
t h e i n s i d e s h o e . W e w i l l m a k e t h e f i n a l
a d j u s t m e n t l a t e r .
R e p e a t o n t h e s e c o n d s h o e .
T r i m a n y b u r r s f r o m t h i s
e d g e o f t h e h o l e s w i t h a
h o b b y k n i f e .
2 2 9 2
2 2 8 9
( s i l v e r )
6 5 9 1
2 2 8 9
2 2 9 2
s t e p 8
2 2 9 2
2 2 9 2
2 2 8 9
2 2 8 9
2 2 8 9
2 2 8 9
2 2 8 6
s h o e a s s e m b l y
s e t s c r e w
( s i l v e r )
s e t s c r e w
N O T E :
I f t h e s h o e a s s e m b l y r o c k s o n t h e s h a f t ,
t i g h t e n t h e s e t s c r e w s s o t h e b a l l s a r e t o u c h i n g
t h e f l a t s , b u t n o t e n o u g h t o s p r e a d t h e s h o e s
a p a r t .
I f t h e s h o e s s t a r t t o s p r e a d a p a r t , l o o s e n t h e
s e t s c r e w t o t a k e p r e s s u r e o f f t h e b a l l .
A d j u s t
b o t h s e t s c r e w s e q u a l l y !
8
5 / 6 4 "
1 : 1
1
2
g e a r m o u n t s t o
s h o u l d e r s i d e
R A C E R ' S T I P :
A f t e r r u n n i n g y o u r c a r f o r a t a n k o f
f u e l , r e m o v e y o u r t w o - s p e e d h o u s i n g a n d c l e a n
a n y o i l o r r e s i d u e f r o m i n s i d e t h e h o u s i n g a n d
o u t s i d e t h e s h o e s t o e n s u r e c o n s i s t e n t s h i f t i n g .
1
2
n u m b e r
s i d e f i r s t
P l a c e y o u r t w o c l u t c h s h o e s t o g e t h e r w i t h t h e n u m b e r s s i d e
f a c i n g u p . S l i d e # 2 2 8 9 a d j u s t m e n t s p r i n g o n t o # 2 2 8 9 a d j u s t m e n t
s c r e w . I n s e r t t h e s c r e w a n d s p r i n g i n t o t h e s h o e s a n d t i g h t e n t h e
s c r e w s u n t i l t h e y a r e f u l l y c o m p r e s s e d . B e g e n t l e ! N o w t u r n t h e
s c r e w 3 ½ t u r n s c o u n t e r c l o c k w i s e . A d j u s t b o t h s c r e w s e q u a l l y .
S l i d e y o u r c l u t c h s h o e a s s e m b l y o n t o # 2 2 8 6 i n p u t s h a f t .
T o a d j u s t t h e p r e s s u r e o f t h e s e t s c r e w : A d j u s t t h e s e t s c r e w s
e q u a l l y s o t h a t t h e b a l l i s j u s t t o u c h i n g t h e f l a t s o n t h e i n p u t s h a f t
a s s h o w n .
B A G C
R E M O V E T H E S E
P A R T S F O R :
S t e p s 1 1 - 1 2
T O O L S U S E D
2 2 9 1 , q t y 2
d o w e l p i n
3 9 0 3 , q t y 1
d r i v e p i n i o n
2 2 8 1 , q t y 1
b r a k e d i s c
2 2 7 0 , q t y 1
d r i v e c u p
1 : 1
5 4 0 7 , q t y 1
r e d O - r i n g
1 : 1
2 2 9 3 , q t y 3
i n p u t s h a f t s h i m
1 : 1
6 9 2 0 , q t y 1
4 - 4 0 x 3 / 1 6 s c r e w
1 : 11 : 1
6 2 9 9 , q t y 1
s m a l l E - c l i p
1 : 1
3 9 7 7 , q t y 2
3 / 1 6 x 3 / 8 b e a r i n g ,
r u b b e r s e a l e d
s t e p 1 1
S l i d e o n e # 3 9 7 7 b e a r i n g a n d t w o # 2 2 9 3
i n p u t s h a f t s h i m s o n t o t h e r e a r i n p u t s h a f t .
I n s t a l l a n d c e n t e r a # 2 2 9 1 d o w e l p i n i n t o t h e i n p u t s h a f t .
S l i d e # 3 9 0 3 d r i v e p i n i o n o n t o t h e e n d o f t h e i n p u t s h a f t .
A d d a # 6 2 9 9 s m a l l e - c l i p .
s t e p 1 2
S l i d e o n o n e # 3 9 7 7 b e a r i n g o n t o t h e o p p o s i t e e n d o f t h e i n p u t
s h a f t f o l l o w e d b y t h e t h i r d # 2 2 9 3 i n p u t s h a f t s h i m .
I n s t a l l a n d c e n t e r a # 2 2 9 1 d o w e l p i n i n t o t h e i n p u t s h a f t .
C l e a n t h e # 2 2 8 1 b r a k e d i s c w i t h m o t o r c l e a n e r . P l a c e # 2 2 8 1
b r a k e d i s c o n t o # 2 2 7 0 d r i v e c u p . S l i d e t h e d r i v e
c u p w i t h b r a k e d i s c o n t o t h e i n p u t s h a f t .
T i g h t e n i t d o w n w i t h o n e # 6 9 2 0 s c r e w .
S l i d e o n e # 5 4 0 7 O - r i n g i n t o d r i v e c u p .
3 9 7 7
2 2 9 3
3 9 0 3
2 2 9 1
6 2 9 9
3 9 7 7
2 2 9 1
2 2 8 1
2 2 7 0
6 9 2 0
5 4 0 7
B A G C
R E M O V E T H E S E
P A R T S F O R :
S t e p s 1 3 - 1 8
T O O L S U S E D
2 2 7 6 , q t y 1
b r a k e c a m
2 2 7 4 , q t y 1
b r a k e b r a c k e t
2 2 7 7 , q t y 1
f l a n g e d b u s h i n g
1 / 8 x 1 / 4
2 6 6 1 , q t y 1
l a r g e E - c l i p
2 2 8 0 , q t y 1
b r a k e c a m
l e v e r w i r e
6 8 6 3 , q t y 1
f l a n g e d b u s h i n g
3 / 1 6 x 5 / 1 6
1 : 1
2 3 6 8 , q t y p r
t r a n s m i s s i o n c a s e s ,
t o p & b o t t o m
6 5 9 1 , q t y 1
d i f f l u b e
2 2 7 8 , q t y 2
b r a k e p a d
2 2 6 9 , q t y 1
c e n t e r b u l k h e a d
1 : 1
6 2 9 2 , q t y 4
4 - 4 0 x 3 / 8 s c r e w
6 9 2 4 , q t y 6
4 - 4 0 x 3 / 8 s c r e w
6 9 2 0 , q t y 1
4 - 4 0 x 3 / 1 6 s c r e w
1 : 1
6 9 2 2 , q t y 2
4 - 4 0 x 1 / 2 s c r e w
6 2 9 1 , q t y 2
4 - 4 0 X 1 / 4 s c r e w
1 : 1 1 : 1 1 : 1
1 : 1 1 : 1
s t e p 1 3
S l i d e # 6 8 6 3 b u s h i n g o n t o t h e e n d o f t h e # 2 2 7 6 b r a k e
c a m .
A n g l e t h e b r a k e c a m w i t h b u s h i n g a n d s l i d e i t t h r o u g h
t h e l a r g e h o l e o f t h e # 2 2 7 4 b r a k e b r a c k e t . P r e s s # 6 8 6 3
b u s h i n g i n t o t h e b r a k e c a m w h i l e s t i l l o n t h e b r a k e c a m .
s t e p 1 4
P l a c e # 2 2 7 7 b u s h i n g i n b e t w e e n t h e b r a k e c a m a n d b r a k e
b r a c k e t a n d p r e s s i t i n t o t h e b r a k e b r a c k e t .
S l i d e t h e b r a k e c a m i n t o t h e b u s h i n g .
A d d # 2 6 6 1 l a r g e E - c l i p .
6 8 6 3
2 2 7 6
2 2 7 4
2 2 7 7
2 6 6 1
9
1 / 1 6 " , 3 / 3 2 "
f l a n g e s i d e f i r s t
T r i m a n y b u r r s f r o m t h i s
e d g e o f t h e d r i v e p i n i o n
w i t h a h o b b y k n i f e .
2 2 9 3
I J A F   # 
S l i d e # 2 2 8 0 b r a k e c a m l e v e r w i r e i n t o t h e b r a k e c a m .
M a k e s u r e t h a t t h e w i r e i s a n g l e d a s s h o w n a t r i g h t .
S l i d e t h e w i r e t h r o u g h t h e s i d e o f t h e c a m s o t h e b r a k e
c a m p i n s a r e f a c i n g u p .
S e c u r e w i t h # 6 9 2 0 s c r e w .
I J A F   $ 
A t t a c h # 2 3 6 8
l o w e r t r a n s m i s s i o n
c a s e t o t h e
c h a s s i s w i t h f o u r
# 6 2 9 2 s c r e w s .
2 2 8 0
6 9 2 0
6 2 9 2
b r a k e c a m p i n s
6 2 9 2
6 2 9 2
6 2 9 2
2 3 6 8
I J A F   % 
P l a c e t h e f r o n t d i f f a s s e m b l y a n d f r o n t i n p u t s h a f t
a s s e m b l y i n t o t h e l o w e r t r a n s m i s s i o n c a s e .
S q u e e z e f o u r b e a d s o f # 6 5 9 1 d i f f l u b e e q u a l l y s p a c e d
a p a r t t o t h e f r o n t s i d e o f t h e r i n g g e a r a n d p i n i o n g e a r .
A t t a c h t h e # 2 3 6 8 u p p e r t r a n s m i s s i o n c a s e t o t h e l o w e r
c a s e w i t h s i x # 6 9 2 4 s c r e w s .
D o n o t o v e r t i g h t e n .
I J A F   & 
A t t a c h t h e b r a k e c a m a s s e m b l y t o t h e c h a s s i s w i t h t w o # 6 2 9 1
s c r e w s .
S l i d e o n e # 2 2 7 8 b r a k e p a d ( s t e e l s i d e f a c i n g b u l k h e a d ) o n t o
t h e # 2 2 6 9 c e n t e r b u l k h e a d . S l i d e t h e s e c o n d # 2 2 7 8 b r a k e p a d
( s t e e l s i d e f a c i n g a w a y f r o m b u l k h e a d ) o n t o t h e # 2 2 6 9 c e n t e r
b u l k h e a d .
A t t a c h c e n t e r b u l k h e a d t o t h e c h a s s i s w i t h t w o # 6 9 2 2 s c r e w s .
6 5 9 1
d i f f a s s e m b l y
f r o n t i n p u t
s h a f t a s s e m b l y
2 3 6 8
6 9 2 4
2 2 7 8
b r a k e c a m
a s s e m b l y
b u l k h e a d
6 2 9 1
6 2 9 1
2 2 6 9
s t e e l s i d e f a c i n g b u l k h e a d
s t e e l s i d e a w a y
f r o m b u l k h e a d
6 9 2 2
2 2 7 8
1 0
T H R E A D L O C K
r e c o m m e n d e d
o n s c r e w s # 6 2 9 1
T H R E A D L O C K
r e c o m m e n d e d
o n s c r e w # 6 9 2 0
n o t e t h e
a n g l e
s t e p 1 9
A t t a c h # 2 3 6 8 l o w e r t r a n s m i s s i o n c a s e
t o t h e c h a s s i s w i t h f o u r # 6 2 9 2 s c r e w s .
2 3 6 8
s t e p 2 0
P l a c e t h e d i f f a s s e m b l y i n t o t h e l o w e r
t r a n s m i s s i o n c a s e .
P l a c e o n e e n d o f t h e # 2 2 6 2 d r i v e s h a f t i n t o t h e r e a r
i n p u t s h a f t a s s e m b l y . T h e s h a f t m a y b e a s l i g h t l y s n u g
f i t i n t h e c u p . I n s t a l l t h e o p p o s i t e e n d i n t o t h e f r o n t d r i v e
c u p .
S e t t h e i n p u t s h a f t i n t o p l a c e , m a k i n g s u r e t h e b r a k e
d i s c i s p l a c e d i n b e t w e e n t h e b r a k e p a d s .
S q u e e z e f o u r b e a d s o f # 6 5 9 1 d i f f l u b e e q u a l l y
s p a c e d a p a r t
t o t h e f r o n t s i d e o f t h e r i n g g e a r
a n d p i n i o n g e a r .
A t t a c h # 2 3 6 8 u p p e r t r a n s m i s s i o n c a s e t o
t h e l o w e r t r a n s m i s s i o n c a s e w i t h s i x
# 6 9 2 4 s c r e w s .
6 2 9 2
6 2 9 2
6 2 9 2
6 2 9 2
2 2 6 2
6 5 9 1
2 3 6 8
6 9 2 4
b r a k e d i s c
b r a k e p a d s
s t e p 2 1
A l i g n t h e # 2 2 6 9 b e a r i n g c a p o v e r t h e b e a r i n g a n d
a t t a c h w i t h t w o # 6 9 2 4 s c r e w s . D o n o t o v e r t i g h t e n .
2 2 6 9
6 9 2 4
2 2 6 9
6 9 2 4
B A G C
R E M O V E T H E S E
P A R T S F O R :
S t e p s 1 9 - 2 1
T O O L S U S E D
2 2 6 2 , q t y 1
m a i n d r i v e s h a f t
6 5 9 1 , q t y 1
S t e a l t h l u b e
2 3 6 8 , q t y 1
l o w e r t r a n s m i s s i o n
c a s e
2 2 6 9 , q t y 1
b e a r i n g c a p
1 : 1
6 9 2 4 , q t y 8
4 - 4 0 x 3 / 8 s c r e w
1 : 1
6 2 9 2 , q t y 4
4 - 4 0 x 3 / 8 s c r e w
11
1 / 1 6 " , 3 / 3 2 "
d i f f
a s s e m b l y
6 9 1 7 , q t y 8
4 - 4 0 x 3 / 8 s c r e w
A t t a c h # 2 2 5 4 r i g h t & l e f t
f r o n t c h a s s i s b r a c e s t o
t h e t r a n s m i s s i o n c a s e
w i t h # 6 9 1 7 s c r e w s a n d
t o t h e c h a s s i s w i t h
# 6 2 9 2 s c r e w s .
B A G D
R E M O V E T H E S E
P A R T S F O R :
S t e p s 1 - 5
2 2 5 4 , q t y p r
f r o n t c h a s s i s b r a c e s ,
l e f t & r i g h t
s t e p 1
T O O L S U S E D
A t t a c h # 2 2 5 4 r i g h t & l e f t
r e a r c h a s s i s b r a c e s t o
t h e t r a n s m i s s i o n c a s e
w i t h # 6 9 1 7 s c r e w s a n d
t o t h e c h a s s i s w i t h
# 6 2 9 2 s c r e w s .
s t e p 2
2 2 5 4
6 9 1 7
2 2 5 4
6 9 1 7
6 2 9 2
2 2 5 4
6 9 1 7
6 2 9 2
2 2 5 4
6 9 1 7
6 2 9 2
2 2 5 4 , q t y p r
r e a r c h a s s i s b r a c e s ,
l e f t & r i g h t
1 : 1
P u s h t h e # 6 2 9 2 s c r e w s
t h r o u g h t h e b o t t o m o f t h e
c h a s s i s a n d p l a c e a # 5 4 0 7
O - r i n g o n e a c h s c r e w .
P l a c e # 2 2 6 0 h a n d l e o n t o
t h e s c r e w s a n d t i g h t e n t h e
s c r e w s t o c o m p r e s s t h e O -
r i n g s .
s t e p 3
I n s t a l l t h e # 7 4 1 3 s c r e w s t h r o u g h t h e m i d d l e h o l e o n t h e # 2 2 5 0
f r o n t / r e a r t o w e r .
T h e n t h r e a d o n t h e # 7 2 6 0 n u t s a n d t i g h t e n .
R e p e a t s t e p f o r s e c o n d t o w e r .
s t e p 4
2 2 6 0
6 2 9 2
6 2 9 2
2 2 6 0 , q t y 1
h a n d l e
2 2 5 0 , q t y 2
t o w e r ( f r o n t o r r e a r )
7 2 6 0 , q t y 4
4 - 4 0 n u t
1 : 1
6 9 2 4 , q t y 6
4 - 4 0 x 3 / 8 s c r e w
6 2 9 2 , q t y 6
4 - 4 0 x 3 / 8 s c r e w
7 4 1 3 , q t y 4
4 - 4 0 x 3 / 4 s c r e w
3
7 4 1 3
7 4 1 3
2 2 5 0
7 2 6 0
7 2 6 0
1 : 11 : 1
1 2
1/16", 3/32"
1 : 1
5 4 0 7
5 4 0 7
5 4 0 7 , q t y 2
r e d O - r i n g
1 : 1
A t t a c h o n e s h o c k t o w e r
a s s e m b l y t o t h e f r o n t
t r a n s m i s s i o n c a s e a n d t h e
s e c o n d o n e t o t h e r e a r
t r a n s m i s s i o n c a s e w i t h
t h r e e # 6 9 2 4 s c r e w s .
s t e p 5
6 9 2 4
6 9 2 4
B A G E
R E M O V E T H E S E
P A R T S F O R :
S t e p 1
6 5 8 8 , q t y 1
b l a c k g r e a s e
T O O L S U S E D
3 8 8 6 , q t y 4
C V D a x l e
C V D A S S E M B L Y
S p r e a d s o m e A s s o c i a t e d # 6 5 8 8 b l a c k g r e a s e
i n s i d e t h e # 3 8 8 6 a x l e h o l e w h e r e s h o w n , t h e n
o n t h e # 7 3 8 1 c o u p l i n g a n d i n s e r t t h e c o u p l i n g
i n t o t h e a x l e .
S l i d e t h e # 3 8 8 6 a x l e i n t o t h e # 3 8 8 8 d o g b o n e ,
a l i g n i n g t h e c r o s s p i n h o l e s .
I n s e r t t h e # 7 3 8 1 c r o s s p i n , m a k i n g s u r e i t i s
e v e n l y s p a c e d o n b o t h s i d e s o f t h e d o g b o n e .
A d d a s m a l l d r o p o f M I P t h r e a d l o c k t o t h e
# 7 3 8 1 s e t s c r e w . A n g l e a n d t u r n t h e C V D s o
t h e s e t s c r e w c a n b e s c r e w e d i n w i t h t h e A l l e n
w r e n c h .
R e p e a t s t e p s f o r t h e t h r e e r e m a i n i n g C V D s .
s t e p 1
S T E E R I N G / H U B C A R R I E R A S S E M B L Y
S l i d e o n e # 3 9 7 7 b e a r i n g o n t o t h e a x l e . S l i d e
t h e a x l e a s s e m b l y i n t o t h e b a c k o f t h e # 2 2 4 7
s t e e r i n g / h u b c a r r i e r
S l i d e i n a # 3 9 6 5 b e a r i n g s p a c e r
I n s t a l l t h e s e c o n d # 3 9 7 7 b e a r i n g i n t o t h e
s t e e r i n g / h u b c a r r i e r , f o l l o w e d b y o n e # 7 3 6 8
t h i n s p a c e r .
I n s e r t t h e # 7 3 6 9 r o l l p i n i n t o t h e a x l e .
R e p e a t s t e p s 6 - 9 f o r t h e t h r e e r e m a i n i n g
s t e e r i n g / h u b c a r r i e r s .
F R O N T :
T h r e a d a # 6 2 7 3 b a l l e n d i n t o t h e
b o t t o m o f o n e r i g h t a n d o n e l e f t s t e e r i n g / h u b
c a r r i e r s f o r t h e f r o n t . A d d a # 7 2 6 0 p l a i n n u t .
R E A R :
T h r e a d a # 2 2 5 7 r e a r t o e b a l l e n d i n t o
t h e b o t t o m o f o n e r i g h t a n d o n e l e f t s t e e r i n g /
h u b c a r r i e r s f o r t h e r e a r . A d d a # 2 2 5 7 l a r g e
p l a i n n u t .
6 5 8 8
3 8 8 6
7 3 8 1
c o u p l i n g
3 8 8 8
d o g b o n e
c r o s s p i n h o l e s
M I P t h r e a d l o c k
# 7 3 8 1
s e t s c r e w
5
1 0
3 9 7 7
2 2 4 7
3 9 6 5
7 3 6 8
7 3 6 9
2 2 5 7
( g o l d )
R E A R
U s e t h i s h o l e i n t h e
r e a r s t e e r i n g /
h u b c a r r i e r s
3 9 7 7
F R O N T
U s e t h i s h o l e i n t h e
f r o n t s t e e r i n g /
h u b c a r r i e r s
7 2 6 0
2 2 5 7
3 8 8 8 , q t y 4
C V D d o g b o n e
7 3 8 1 , q t y 1
M I P t h r e a d l o c k
2 2 4 7 , q t y 2 p r
s t e e r i n g / h u b c a r r i e r
l e f t a n d r i g h t
3 9 6 5 , q t y 4
b e a r i n g s p a c e r
7 3 6 8 , q t y 4
t h i n s p a c e r
7 3 6 9 , q t y 4
r o l l p i n
6 2 7 3 , q t y 2
b a l l e n d
( s i l v e r )
7 2 6 0 , q t y 2
4 - 4 0 p l a i n n u t
2 2 5 7 , q t y 2
r e a r t o e b a l l e n d
( g o l d )
2 2 5 7 , q t y 2
6 - 3 2 p l a i n n u t
7 3 8 1
c r o s s p i n
3 9 7 7 , q t y 8
3 / 1 6 x 3 / 8 b e a r i n g ,
r u b b e r s e a l e d
1 : 1
7 3 8 1 , q t y 4
C V D c o u p l i n g
7 3 8 1 , q t y 4
C V D c r o s s p i n
7 3 8 1 , q t y 4
C V D s e t s c r e w
1 : 1 1 : 1 1 : 1
1 : 1
1 : 1
1 : 1
1 : 1 1 : 1
1 : 1
1 : 1
1 3
. 0 5 0 "
3 / 1 6 " , 1 . 4 "
L E F T
f r o n t & r e a r b l o c k s
R I G H T
f r o n t & r e a r b l o c k s
L
R
6 2 7 3
( n a t u r a l )
BLACK GREASE
BLACK GREASE
B A G E
R E M O V E T H E S E
P A R T S F O R :
S t e p s 2 - 4
2 2 4 6 , q t y 8
p i v o t b a l l
T O O L S U S E D
2 2 4 9 , q t y 8
s o c k e t c a p
I n s e r t o n e # 2 2 4 6 p i v o t b a l l i n t o t h e u p p e r s o c k e t a n d
o n e i n t o t h e l o w e r s o c k e t o f t h e s t e e r i n g / h u b c a r r i e r
a s s e m b l i e s .
I n s e r t t h e # 2 2 4 9 s o c k e t c a p s a n d s e c u r e t h e m d o w n
w i t h # 6 9 2 4 s c r e w s . T i g h t e n t h e s o c k e t c a p s c r e w s s o
t h a t t h e p i v o t b a l l m o v e s f r e e l y w i t h o u t a n y b i n d i n g o r
e x c e s s p l a y .
R e p e a t f o r t h e r e m a i n i n g t h r e e s t e e r i n g / h u b c a r r i e r s .
s t e p 2
2 2 3 3 , q t y p r
f r o n t u p p e r
s u s p e n s i o n a r m ,
l e f t a n d r i g h t
3
2 2 4 6
2 2 4 9
6 9 2 4
2 2 4 6
2 2 4 9
6 9 2 4
6 9 2 4
6 9 2 4
F R O N T U P P E R S U S P E N S I O N A R M
A d d a s m a l l a m o u n t o f # 6 5 8 8 b l a c k g r e a s e t o t h e e n d o f t h e
t h r e a d s o n t h e p i v o t b a l l .
U s e y o u r 5 / 6 4 " A l l e n w r e n c h t o s c r e w t h e p i v o t b a l l i n t o t h e
# 2 2 3 3 l e f t f r o n t u p p e r s u s p e n s i o n a r m . D o n o t t h r e a d p i v o t b a l l
a l l t h e w a y i n .
R e p e a t f o r t h e r i g h t f r o n t .
s t e p 3
3
R E A R U P P E R S U S P E N S I O N A R M
A d d a s m a l l a m o u n t o f # 6 5 8 8 b l a c k g r e a s e t o t h e e n d o f t h e
t h r e a d s o n t h e p i v o t b a l l .
U s e y o u r 5 / 6 4 " A l l e n w r e n c h t o s c r e w t h e p i v o t b a l l i n t o t h e
# 2 2 4 3 l e f t r e a r u p p e r s u s p e n s i o n a r m .
D o n o t t h r e a d p i v o t b a l l a l l t h e w a y i n .
R e p e a t f o r t h e r i g h t r e a r .
s t e p 4
2 2 3 3
2 2 4 3
l e f t f r o n t a s s e m b l y
l e f t r e a r a s s e m b l y
2 2 4 3 , q t y p r
r e a r u p p e r
s u s p e n s i o n a r m ,
l e f t a n d r i g h t
A d d a s m a l l a m o u n t o f # 6 5 8 8 b l a c k g r e a s e t o
t h e e n d o f t h e t h r e a d s o n t h e p i v o t b a l l .
U s e y o u r A l l e n w r e n c h t o s c r e w t h e p i v o t b a l l
i n t o t h e # 2 2 3 3 f r o n t l o w e r s u s p e n s i o n a r m .
S l i d e y o u r s u p p l i e d t r a c k w i d t h g a u g e i n
b e t w e e n t h e s t e e r i n g / h u b c a r r i e r a s s e m b l y
a n d t h e l o w e r a r m .
U s e y o u r 5 / 6 4 " A l l e n w r e n c h t o t i g h t e n t h e
p i v o t b a l l u n t i l t h e g a u g e i s s a n d w i c h e d i n
b e t w e e n t h e t w o .
T u r n t h e p i v o t b a l l c o u n t e r c l o c k w i s e u n t i l t h e
g a u g e c a n b e r e m o v e d .
R e p e a t f o r t h e l o w e r s u s p e n s i o n a r m s f o r t h e
r i g h t f r o n t , l e f t r e a r , a n d t h e r i g h t r e a r .
s t e p 5
5
t r a c k w i d t h g a u g e
2 2 3 3
6 9 2 4 , q t y 1 6
4 - 4 0 x 3 / 8 s c r e w
1 : 1
C o m p a r e t h e f r o n t a n d
r e a r u p p e r a r m s .
O p e n i n g A ( f r o n t u p p e r a r m )
i s w i d e r t h a n
o p e n i n g B
( r e a r u p p e r a r m )
1 4
3 / 3 2 " , 5 / 6 4 "
6 5 8 8
3
6 5 8 8
6 5 8 8
1 : 1
2 2 3 5
9 1 4 6
2 2 3 9
2 2 3 9
B A G E
R E M O V E T H E S E
P A R T S F O R :
S t e p s 6 -
2 2 3 5 , q t y 2
f r o n t h i n g e p i n
T O O L S U S E D
9 1 4 6 , q t y 4
2 / 5 6 x 3 / 1 6 s c r e w
1 : 1
L i n e u p t h e # 2 2 3 3 f r o n t u p p e r s u s p e n s i o n a r m w i t h t h e i n n e r
h o l e o n t h e s h o c k t o w e r , m a k i n g s u r e t h e C V D d o g b o n e i s i n
t h e s l o t s o f t h e o u t d r i v e . P u s h a # 2 2 3 5 h i n g e p i n i n t o t h e a r m
a n d t h e s h o c k t o w e r .
F a s t e n # 9 1 4 6 s c r e w i n t o t h e u p p e r a r m . T h e s c r e w h o l d s i n
t h e h i n g e p i n .
C l i p i n t h e t w o # 2 2 3 9 c a s t e r c l i p s . P l a c e o n e o n e a c h s i d e o f
t h e t o w e r . T h i s s e t s y o u r c a s t e r a t 9 d e g r e e s .
R e p e a t s t e p 6 f o r t h e r i g h t f r o n t .
s t e p 6
2 2 3 9 , q t y 4
c a s t e r c l i p
2 2 3 5 , q t y 2
r e a r h i n g e p i n
4
6 2 6 4 , q t y 2
s t e e r i n g l i n k
t u r n b u c k l e
6 2 7 4 , q t y 4
b a l l c u p ,
b l a c k
L i n e u p t h e # 2 2 4 3 r e a r u p p e r s u s p e n s i o n a r m w i t h t h e
i n n e r h o l e o n t h e s h o c k t o w e r , m a k i n g s u r e t h e C V D
d o g b o n e i s i n t h e s l o t s o f t h e o u t d r i v e s . P u s h # 2 2 3 5 h i n g e
p i n i n t o t h e a r m a n d t h e t o w e r .
F a s t e n # 9 1 4 6 s c r e w i n t o t h e u p p e r a r m .
R e p e a t s t e p 7 f o r t h e r i g h t r e a r .
s t e p 7
3
2 2 3 5
9 1 4 6
T w i s t t h e # 6 2 7 4 b a l l c u p s o n t o t h e # 6 2 6 4 t u r n b u c k l e u n t i l
y o u g e t t h e d i m e n s i o n s h o w n ( s t e e r i n g t u r n b u c k l e ) .
A s s e m b l e b o t h t u r n b u c k l e s .
T w i s t t h e # 2 2 5 1 g r a y b a l l c u p s o n t o t h e # 2 2 5 3 r e a r t o e
t u r n b u c k l e u n t i l y o u g e t t h e d i m e n s i o n s h o w n ( r e a r t o e
t u r n b u c k l e ) . A s s e m b l e b o t h t u r n b u c k l e s . T h i s r e s u l t s i n 2 °
r e a r t o e .
S n a p a l l f o u r t u r n b u c k l e s i n t o p l a c e w h e r e s h o w n .
s t e p 8
6 2 7 4
( b l a c k )
6 2 6 4
2 2 5 1
( g r a y )
2 2 5 3
6 2 7 4
( b l a c k )
s t e e r i n g l i n k t u r n b u c k l e r e a r t o e t u r n b u c k l e
1 . 8 0 "
4 5 . 9 m m
2 . 0 2 "
5 1 . 4 m m
T o s c r e w b a l l c u p o n t o t u r n b u c k l e :
1 . G r i p m i d d l e o f t u r n b u c k l e w i t h n e e d l e n o s e p l i e r s .
2 . T h r e a d o n b a l l c u p b y h a n d a t f i r s t , t h e n u s e t u r n b u c k l e
t o o l t o f i n i s h .
3 . S q u e e z e t u r n b u c k l e o n t o b a l l e n d w i t h n e e d l e n o s e p l i e r s .
2 2 5 3 , q t y 2
r e a r t o e
t u r n b u c k l e
2 2 5 1 , q t y 4
b a l l c u p ,
g r a y
1 : 1 1 : 11 : 1
1 : 1
1 : 1
F R O N T
R E A R
1 5
2 2 5 1
( g r a y )
. 0 5 0 "
s t e p 1
6 4 6 4
T R I M S H O C K P I S T O N
B u r r s o n t h e # 6 4 6 5 s h o c k
p i s t o n i n t e r f e r e w i t h s m o o t h
s h o c k a c t i o n w i t h i n t h e s h o c k
b o d y . T o r e m o v e f r o m t r e e
w i t h o u t c r e a t i n g b u r r s , t w i s t u p ,
n o t d o w n . R e m o v e t w o # 2 a n d
t w o # 3 s h o c k p i s t o n s .
R e m o v e r e m a i n i n g b u r r s
c a r e f u l l y w i t h a h o b b y k n i f e .
b u r r
w r o n g
r i g h t
V C F O A M A N D B O B B I N
S o a k t h e # 8 4 5 6 V C f o a m
w i t h # 5 4 2 3 4 0 w t s h o c k o i l
a n d i n s t a l l i t o n t o t h e
# 8 4 5 6 V C b o b b i n .
5 4 2 3
O I L
8 4 5 6
f o a m
8 4 5 6
b o b b i n
a s s e m b l e d
s t e p 2
3 9 6 3 , q t y 4
t h r e a d e d m a c r o s h o c k b o d y
b l u e
B A G F
R E M O V E T H E S E
P A R T S F O R :
S t e p s 1 - 4
T O O L S U S E D
16
5 4 0 7 , q t y 8
r e d O - r i n g
5 4 2 3 , q t y 1
4 0 w t
s i l i c o n e o i l
1 : 1
6 4 6 9 , q t y 4
l a r g e O - r i n g
6 2 9 9 , q t y 8
E - c l i p
1 : 1
1 : 1
8 8 4 4 , q t y 4
s h o c k s h a f t ,
. 3 9 s t r o k e
8 4 5 6 , q t y 4
V C f o a m
1 : 1
8 4 5 6 , q t y 4
V C b o b b i n
6 4 2 8 , q t y 4
s h o c k c a p
7 2 1 7 , q t y 4
s h o c k p i v o t b a l l
7 2 1 7 , q t y 4
s h o c k e y e l e t
1 : 1
s t e p 3
I n s e r t t h e a s s e m b l y i n t o t h e s h o c k b o d y a n d p u l l
t h e s h a f t t h r o u g h f i r m l y t o s e a t t h e V C b o b b i n a t
t h e b a s e o f t h e s h o c k b o r e .
P u s h t h e # 7 2 1 7 p i v o t b a l l a n d e y e l e t t o g e t h e r . A s
y o u h o l d t h e s h a f t w i t h a r a g a n d n e e d l e n o s e
p l i e r s n e x t t o t h r e a d s , s c r e w t h e e y e l e t s o n t o t h e
e n d o f t h e s h o c k s h a f t .
T I P :
U s e a p e r m a n e n t m a r k e r t o m a r k y o u r s h o c k s
w i t h a n F a n d R t o d e s i g n a t e f r o n t
a n d r e a r .
5 4 2 3
O I L
I N T E R N A L S H O C K A S S E M B L Y
( A s s e m b l e a l l f o u r s h o c k s a t o n c e . )
I n s t a l l t h e # 6 4 6 9 O - r i n g o v e r t h e
t h r e a d s o f t h e # 3 9 6 3 s h o c k b o d y .
O n t h e # 8 8 4 4 s h o c k
s h a f t , i n s t a l l a # 6 2 9 9
E - c l i p o n b o t h s i d e s o f
t h e # 6 4 6 5 # 2 a n d # 3
p i s t o n s f r o m s t e p # 1 .
S l i d e t h e V C f o a m / b o b b i n a s s e m b l y
o v e r t h e # 8 8 4 4 s h a f t a n d t h e n t w o
# 5 4 0 7 O - r i n g s . P l a c e a c o u p l e d r o p s
o f o i l o n t h e O - r i n g s .
6 4 6 5 , q t y 2
s h o c k p i s t o n # 2
r e a r
1 : 1
6 4 6 5 , q t y 2
s h o c k p i s t o n # 3
f r o n t
1 : 1
6 4 6 9
8 8 4 4
6 2 9 9
6 4 6 5 # 3 f r o n t
6 4 6 5 # 2 r e a r
5 4 0 7
7 2 1 7 p i v o t b a l l
7 2 1 7 e y e l e t
6 2 9 9
V C f o a m /
b o b b i n a s s e m b l y
3 9 6 3
B A G F
R E M O V E T H E S E
P A R T S F O R :
S t e p s 5 - 8
T O O L S U S E D
1 : 1
6 9 2 5 , q t y 4
4 - 4 0 x 1 / 2 s c r e w
6 4 7 5 , q t y 4
s p r i n g c u p
3 9 4 6 , q t y 2
s p r i n g , c o p p e r , f r o n t
3 9 4 4 , q t y 2
s p r i n g , g o l d , r e a r
6 4 7 3 , q t y 4
s h o c k b u s h i n g
3 / 3 2 "
1 : 1
3 9 5 9 , q t y 4
s h o c k c o l l a r O - r i n g
6 4 2 8
H o l d i n g t h e s h o c k
u p r i g h t , f i l l w i t h o i l
t o t h e t o p o f t h e b o d y .
S l o w l y m o v e t h e
s h a f t u p a n d d o w n
s e v e r a l t i m e s t o
a l l o w a i r b u b b l e s
t o e s c a p e t o t h e t o p .
R e f i l l w i t h o i l t o t h e
t o p o f t h e b o d y .
P u s h t h e s h a f t u p u n t i l
t h e p i s t o n i s l e v e l w i t h
t h e t o p o f t h e b o d y .
T h e o i l w i l l b u l g e u p
a b o v e t h e s h o c k b o d y .
F i l l T h e # 6 4 2 8 s h o c k c a p a b o u t
h a l f w a y w i t h o i l a n d i n s t a l l o n t o
t h e b o d y . T r y t o r e t a i n a s m u c h
o i l a s p o s s i b l e d u r i n g a s s e m b l y .
T h e s h a f t w i l l e x t e n d o u t a s y o u
t i g h t e n t h e c a p d o w n .
s t e p 4
S E T T I N G T H E
R E B O U N D
M o v e t h e s h o c k s h a f t
i n a n d o u t a f e w t i m e s
a n t h e n p u s h i t a l l t h e
w a y i n . I t s h o u l d b e
e a s y t o p u s h t h e s h a f t
i n u n t i l t h e e y e l e t h i t s
t h e b o d y
T h e n t h e
s h a f t s h o u l d
p u s h i t s e l f
o u t t o i t s f u l l
l e n g t h v e r y
s l o w l y .
I f t h e s h o c k
d o e s n o t p u s h
o u t t h i s f a r
t h e r e i s n o t
e n o u g h o i l i n i t .
A d d a d r o p o f
o i l a n d t r y s t e p s
6 - 7 a g a i n .
I f t h e s h o c k r e b o u n d s t o o
f a s t , o r y o u c a n n o t p u s h t h e
s h a f t i n u n t i l t h e e y e l e t h i t s
t h e b o d y , t h e r e i s t o o m u c h
o i l . L o o s e n t h e c a p a b o u t a
f u l l t u r n a n d p u m p o u t a s m a l l
a m o u n t o f o i l b y p u s h i n g t h e
s h a f t i n . R e t i g h t e n t h e c a p
a n d t r y s t e p s 6 - 7 a g a i n .
T o o m u c h o i l i n t h e s h o c k
w i l l r e s u l t i n l e a k a g e .
9
O I L
O I L
O I L
O I L
3 9 6 3 , q t y 4
s h o c k c o l l a r
S l i d e o n e # 3 9 5 9
b l a c k O - r i n g i n t o
t h e g r o o v e i n t h e
# 3 9 6 3 t h r e a d e d
s h o c k c o l l a r .
P u t o n e d r o p o f o i l o n
t h e O - r i n g b e f o r e y o u
t h r e a d o n t h e s h o c k
c o l l a r .
T h r e a d o n t h e s h o c k
c o l l a r . M a k e s u r e t h a t
t h e s h o u l d e r i s f a c i n g
d o w n w h e n t h r e a d e d
o n t h e b o d y .
O I L
s t e p 5
s h o u l d e r f a c e s d o w n
5 4 2 3
3 9 5 9
3 9 6 3
1 : 1
6 4 7 2 , q t y 4
s h o c k n u t ,
s m a l l
s t e p 6
S l i d e t h e # 3 9 4 6 c o p p e r s p r i n g s o n
t h e f r o n t s h o c k s , a n d # 3 9 4 4 g o l d
s p r i n g s o n t h e r e a r s h o c k s .
C o m p r e s s t h e s p r i n g t o a d d t h e
# 6 4 7 5 s p r i n g c u p t o a l l f o u r s h o c k s .
F R O N T :
3 9 4 6 c o p p e r
R E A R :
3 9 4 4 g o l d
6 4 7 5
1 7
3 / 1 6 "
s t e p 7
F R O N T S H O C K M O U N T I N G
A d d t h e # 6 4 7 3 s h o c k b u s h i n g t o t h e
f r o n t s h o c k t o w e r s c r e w s h o w n .
P u s h t h e s h o c k c a p o v e r t h e
b u s h i n g a n d a d d a # 6 4 7 2 s h o c k
n u t .
D o n o t o v e r t i g h t e n o r t h e
s h o c k w i l l b i n d .
F a s t e n t h e s h o c k e y e l e t i n t o t h e
o u t e r h o l e o f t h e a r m w i t h a # 6 9 2 5
s c r e w .
R e p e a t s t e p s f o r s e c o n d f r o n t
s h o c k .
s t e p 8
4
R E A R S H O C K M O U N T I N G
A d d t h e # 6 4 7 3 s h o c k b u s h i n g t o t h e
r e a r s h o c k t o w e r s c r e w s h o w n .
P u s h t h e s h o c k c a p o v e r t h e
b u s h i n g a n d a d d # 6 4 7 2 s h o c k n u t .
D o n o t o v e r t i g h t e n o r t h e s h o c k
w i l l b i n d .
F a s t e n t h e s h o c k e y e l e t i n t o t h e
o u t e r h o l e o f t h e a r m w i t h a # 6 9 2 5
s c r e w .
R e p e a t s t e p s f o r s e c o n d r e a r s h o c k .
Y o u r f r o n t a n d r e a r s h o c k c o l l a r s s e t
r i d e h e i g h t . F o r m o r e i n f o r m a t i o n o n
r i d e h e i g h t , s e e p a g e 3 0 .
4
6 4 7 3
6 4 7 2
6 9 2 5
6 4 7 2
6 4 7 3
6 4 7 3
6 9 2 5
s t e p 1
I n s e r t # 2 2 5 8 r e c e i v e r
b o x i n t o t h e # 2 2 5 6
r a d i o t r a y a n d s e c u r e
w i t h f o u r # 9 1 4 6
s c r e w s .
B A G H
R E M O V E T H E S E
P A R T S F O R :
S t e p s 1 - 5 B
T O O L S U S E D
2 2 5 8 , q t y 1
r e c e i v e r b o x
1 : 1
2 2 5 8
9 1 4 6
2 2 5 6
9 1 4 6
9 1 4 6
2 2 5 6 , q t y 1
r a d i o t r a y
9 1 4 6 , q t y 4
2 - 5 6 x 3 / 1 6 s c r e w
9 1 8 0 , q t y 4
s e r v o h o r n
3 8 5 7 , q t y 1
s h o r t s p e c i a l
b a l l e n d , b l a c k
7 3 3 6 , q t y 2
s e r v o m o u n t
7 3 3 7 , q t y 8
s t e e l w a s h e r
6 9 1 7 , q t y 8
4 - 4 0 x 3 / 8 s c r e w
1 : 1
1 : 1
1 : 1
3 7 2 0 , q t y 2
w i r e t i e , 8 "
3 7 1 8 , q t y 1
w i r e t i e , 1 2 "
1 : 1
7 3 3 6 q t y 2 t h i n ( . 0 5 0 " )
o f f s e t s p a c e r q t y 2 t h i c k ( . 1 0 0 " )
1 : 1
2 2 3 8 , q t y 2
t h r o t t l e s e r v o s p a c e r
m e d ( . 0 8 0 " )
s t e p 1
P u s h t h e # 7 6 7 3
s c r e w s t h r o u g h
t h e b o t t o m o f t h e
c h a s s i s a n d p l a c e
a # 5 4 0 7 r e d O -
r i n g o n e a c h
s c r e w .
S e t t h e # 7 7 2 1
t a n k o n t o t h e
s c r e w s a n d
t i g h t e n t h e s c r e w s
j u s t e n o u g h t o
s l i g h t l y c o m p r e s s
t h e O - r i n g s s o t h e
t a n k c a n ' t m o v e
a r o u n d .
B A G G
R E M O V E T H E S E
P A R T S F O R :
S t e p 1
T O O L S U S E D
7 6 7 3 , q t y 3
4 - 4 0 x 5 / 1 6 s c r e w
5 4 0 7 , q t y 3
r e d O - r i n g
7 7 2 1 , q t y 1
f u e l t a n k
1 : 1 1 : 1
5 4 0 7
7 6 7 3
7 6 7 3
7 6 7 3
7 7 2 1
1 / 1 6 "
1 8
. 0 5 0 " , 1 / 1 6 "
3 / 1 6 "
6 9 1 8 , q t y 4
4 - 4 0 x 1 / 2 s c r e w
1 : 1
2 2 5 2 , q t y 1
b a t t e r y m o u n t
C A U T I O N :
T h e b o x
w i l l f i t t i g h t .
I J A F  "
Look at the chart at right to see if a #2238 spacer is
needed for your throttle servo. Attach the spacer if any, in
between the radio tray and servo with the #7337 washers
and #6918 screws.
Airtronics
94102
Airtronics
94738, 94157, 94158, 94257, 94258, 94357, 94358,
94452, 94453, 94751, 94755
Hitec
HS-5625MG, HS-5645MG, HS-625MG, HS645MG
HS-303, HS-300BB, HS-945MG, HS-925MG, HS-
5945MG, HS-5925MG, HS-525MG, HS-525BB, HS-
425BB, HS-422
JR
Z4725, Z4750, Z2750, Z8450, Z8550, NES-4750
JR
Z250, Z550
Futaba
S9204, S9250, S9450, S148, S3003, S9202, S9101
Futaba
S9404
KO
PS-401
KO
PS-2001, PS-2004, PS-2015, PS-2173, PS-2174, PS-
2123, PS-2143, PS-2144
THROTTLE SERVO TYPE
#2238
SPACER
SERVO
HORN
no spacer
A
spacer A
no spacer
H
no spacer A
spacer
A
no spacer F
spacer F
spacer A
no spacer A
I J A F  # )
USING A BATTERY HARNESS OR 5 CELL HUMP PACK
Place your batteries into your stock radio battery harness.
Attach your harness to the #2252 battery mount with two
#3720 wire ties, making sure the harness wires are facing the
receiver box.
Place the battery harness assembly up into the radio tray and
fasten down with #6917 screws.
Attach the switch to the radio tray with the stock switch
screws.
3720
stock switch screws
2256
receiver box
6917
stock radio switch
stock switch plate
6917
2252
4 cell
battery
holder
2238
spacer
7337
7337
69186918
6918
6918
2238
spacer
wire &
plug
I J A F  # *
USING A FLAT 5 CELL RECEIVER PACK
Place the receiver battery underneath the radio tray as
shown, making sure to place it so the battery wire is facing
the receiver box.
Secure it down with #3718 wire tie by sliding the tie into the
first opening and wrapping it around the battery and sliding it
up through the second opening.
If you use a switch see step 5 #3 at left.
first opening
second opening
flat receiver
battery pack
3718
CHOOSE ONE OF THE STEPS BELOW DEPENDING
ON HOW YOUR RECEIVER BATTERIES MOUNT
20
s t e p 6
F e e d y o u r s w i t c h w i r e s i n t o l o c a t i o n
1 .
F e e d y o u r s t e e r i n g s e r v o w i r e i n t o
2
.
F e e d y o u r t h r o t t l e s e r v o w i r e i n t o
3 .
F e e d y o u r b a t t e r y w i r e s i n t o
4 .
B A G H
R E M O V E T H E S E
P A R T S F O R :
S t e p s 6 - 8
T O O L S U S E D
s t e p 7
P l a c e a p i e c e o f # 6 7 2 7 s e r v o t a p e t o t h e b o t t o m
o f t h e r e c e i v e r .
F e e d t h e a n t e n n a w i r e t h r o u g h t h e s m a l l h o l e i n t h e
r e c e i v e r b o x . B e f o r e p l a c i n g t h e r e c e i v e r , m o v e t h e
w i r e o f f t o t h e s i d e o f t h e b o x a n d t h e n p l a c e t h e
r e c e i v e r i n t o t h e b o x .
C l o s e t h e b o x a n d s l i p a # 6 3 3 2 b o d y c l i p i n t o h o l d i t
s h u t .
T a k e y o u r a n t e n n a w i r e a n d p u s h i t t h r o u g h t h e b u i l t
i n a n t e n n a m o u n t i n t h e r a d i o t r a y .
S l i d e t h e w i r e t h r o u g h # 6 3 3 8 a n t e n n a a n d p u s h t h e
a n t e n n a t u b e f i r m l y i n t o t h e m o u n t . L e a v e s o m e s l a c k
a t t h e b o t t o m . D o n o t c u t o f f e x c e s s a n t e n n a w i r e . C a p
t h e o t h e r e n d w i t h t h e b l a c k r u b b e r c a p .
6 3 3 8 , q t y 1
a n t e n n a t u b e a n d c a p
6 7 2 7 , q t y 1
s e r v o t a p e
6 3 3 2 , q t y 1
b o d y c l i p
6 7 2 7
a n t e n n a w i r e
6 3 3 2
6 3 3 8
6 3 3 8
6 3 3 8
s t e p 8
T w i s t # 6 2 7 4 b a l l c u p s o n t o t h e # 3 8 6 7
t u r n b u c k l e u n t i l y o u g e t t h e d i m e n s i o n
s h o w n .
S n a p o n e e n d o f t h e b a l l e n d o n t o t h e
s e r v o a r m .
P l a c e t h e r a d i o t r a y t e m p o r a r i l y o n t h e
c h a s s i s . S n a p t h e s e c o n d e n d o f t h e
t u r n b u c k l e o n t o t h e b a l l e n d o f t h e
s w i n g r a c k . N o w p l a c e t h e r a d i o t r a y
i n t o p l a c e .
B e f o r e a t t a c h i n g s c r e w s m a k e s u r e t h e
w i r e s f r o m y o u r r e c e i v e r b o x a r e l y i n g
f l a t s o t h e y w o n ' t g e t s m a s h e d .
A t t a c h
t h e r a d i o t r a y w i t h f o u r # 6 9 1 7 s c r e w s
f o r t h e t o p a n d t w o # 6 2 9 2 s c r e w s f o r
t h e b o t t o m .
1 . 5 9 "
4 0 . 5 m m
6 2 7 4
3 8 6 7
6 2 7 4
1 : 1
1 : 1
6 9 1 7
6 9 1 7
6 9 1 7
6 9 1 7
6 2 9 2
6 2 9 2
3 8 6 7 , q t y 1
s t e e r i n g t u r n b u c k l e
1 : 1
6 2 7 4 , q t y 2
b a l l c u p
1 : 1
1 : 1
6 2 9 2 , q t y 2
4 - 4 0 x 3 / 8 s c r e w
6 9 1 7 , q t y 4
4 - 4 0 x 3 / 8 s c r e w
2 1
l e a v e s o m e s l a c k a t t h e b o t t o m
1 / 1 6 "
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AE Nitro TC3 RTR User manual

AE
Brand
AE
Model
Nitro TC3 RTR
Type
User manual
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