page 15
any other balls except our #6581 carbide diff balls The
tolerances we use are tighter than most other companys'.
Due to these tight tolerances and careful packaging of
matched balls, when replacing lost or worn 3/32" diff
balls, you MUST replace ALL 3/32" balls at the same time
with new balls from the same package. This means you
cannot even mix balls from two separate #6581 packag-
es.
(4) Look at the center hole of the #7664 diff gear. If
there is any flash on the inside hole you must remove it. Take
your X-acto© knife and carefully trim the flash from the center
hole. You can make sure you do not remove any of the gear
itself by using the tip of the X-acto© blade, which turns easier
in the hole when removing the flash.
(5) From the Assoc. transmission bag remove the
#6591 Assoc. silicone diff lube tube. Another word of caution.
DO NOT substitute any other type of diff lube on the balls. It
took us countless hours of testing to find the correct silicone
diff lube to make the diff work correctly. Do yourself a favor:
Use what comes in this kit!
WARNING! Do not use the #6588
black grease on the #6581 3/32" diff balls. Fill the twelve ball
holes in the diff gear with silicone diff lube (6) and then push
the twelve #6581 3/32" balls into the holes. (7) Wipe the
excess lube back into the ball holes with your finger. Fig. 45
shows your completed diff gear. (8) Carefully clean all of the
silicone grease off your hands.
Fig. 43
❏
Figs. 44 & 45
(1) Next open bag B, from the
Assoc. transmission bag. (Remember this will be the only
transmission bag that will be different between the different
kit versions) If you have a ball bearing kit you will be using the
parts and part numbers shown on the left side of fig. 44. If you
have a bushing kit you will be using the parts and part
numbers shown on the right side. All kits (bushing and ball
bearing) will use a #6596 bushing for the torque clutch. If you
have a ball bearing kit you will have eight bearings and one
bushing while the bushing kits will have nine bushings.
Note:
All the bushings used in the kit are pre-oiled through a special
manufacturing process, so no oil in needed on the bushings
during the assembly. In this bag you will find a total of eight
bearings and one bushing. (2) Remove one of the #6589
5/32" x 5/16" unflanged ball bearings or one of the #6597
5/32" x 5/16" unflanged bronze bushings.
WARNING!! On
bushing kits both the #6596 and #6597 bushings have
the same outside diameter; only the inside diameter is
different. Do not use the larger inside diameter bushing
for this step. If you do, the torque clutch will not go
together later in the assembly and you will have to take
the transmission and differential apart again to switch
the #6596 for the correct #6597 bushing. (3) Place the
#6589 ball bearing or #6597 bushing into the center hole of
the #7664 differential gear as shown in fig. 45.
Fig. 44
Fig. 45
#6 589
5 /3 2 x 5/1 6
u nfla ng ed b ea rin g
❏
Figs. 46, 47, 48 & 49
(1) In bag A you will find
the molded #6575 T-nut and diff thrust bolt cover (see fig. 46).
(2) Trim the two parts from the nylon runner. We will use it
near the end of the transmission assembly.
WARNING!
Make certain that you do not cut off the “ears” on the T-
nut or the thrust bolt cover. The ears are needed to
prevent the parts from spinning freely in the outdrives.
For now set the diff thrust bolt cover aside; we will use it near
the end of the transmission assembly.
(3) Now remove the #6582 diff thrust spring and the
#7668 left diff outdrive hub (the one with the small nipple on
it) from the same bag A.
WARNING!! Please make sure you
do not get the #6582 diff thrust spring mixed up with the
#6587 torque control spring (from bag E) used later
during the assembly. The torque control spring has a
slightly larger outside diameter and will jamb inside the
diff outdrive hub if forced in. Now check to make sure that
there are no burrs or residue on the inside or outside, of the
