AE Nitro TC3 RTR 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
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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
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 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 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 i s a r r a n g e d s o t h a t 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 o u g o o n t o t h e n e x t b a g .
S o m e t m e s y o u
w l l h a v e p a r t s r e m a n n g a t t h e e n d o f a b a g . T h e s e w 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 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 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 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 , 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 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 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 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 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 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
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 o u s h o u l d h a v e h a n d 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 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 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 o u w h i c h w a 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 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
o u r w a f a s t e r
s t e p 1
3 9 2 9 , q t 1
s p r i n g
6 9 1 8 , q t 1
4 - 4 0 x 1 / 2 " s c r e w
2 2 2 8 , q t 1
s w i n g r a c k
4 4 4 9 , q t 1
4 - 4 0 l o c k n u t
2 2 2 8 , q t 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 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 1
. 1 2 5 x . 2 5 0 r a c k
s h i m
1/16"
3/16"

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
Slide the #2229 pivot post through the
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 .
Slide one #7337 w asher onto the #2229
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 . o w t i g h t e n d o w n t h e s c r e w ,
but not to the point of dam aging the
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 .
Slide one #2234 3/16 x 5/16" bushing
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 .
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
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 m m e n d e d
n s c r e w s # 6 2 9 1
1/16"
1 / 1 6 " , 5 / 6 4 " , 3 / 3 2 "
3/16"
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 .
Slide the #2242 hinge pins through the #2233 arm s. S lide the
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 .
Slide the #2242 hinge pins through the #2243 rear arm s. Slide
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
gear.
Add a generous am ount of #6 91 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 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 o i l r e s i d u e t h o r o u g h l 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 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 8 2 d i f f
spring into the #2328 long outdrive.
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 .
Insert one #6909 bearing into the face of the long outdrive.
A d d a l i g h t c o a t o f # 6 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 o i l r e s i d u e t h o r o u g h l w h e r e s h o w n .
H o l d t h e
# 6 7 3 d i f f b o l t w i t h y o u r / 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 7 3
t h r u s t w a s h e r o n t o t h e # 6 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 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 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 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 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 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 9 1 , q t y 1
Tranny l u b e
6
2 3 3 2
2 3 2 9
6 9 1
6 8 1
6 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 / 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 8 1 , q t y 2 4
d i f f b a l l s
6 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 7 3 , q t y 4
t h r u s t w a s h e r
1 : 1
6 7 , q t y 2
d i f f b o l t
6 8 8 , q t y 1
b l a c k g r e a s e
1 : 1
6 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
/ 6 4 "
3 9 7 6 , q t y 4
3 / 8 x / 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 9 1
6 7 3
6 7 3
6 8 8
6 7 4
6 7 3
2 3 2 8
6 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 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
Place one #2293
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 .
Place one #3976
bearing over each
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
Install and center the #2291 dow el pin into the #3920 front
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 ake
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 .
Slide tw o #2293 input shaft shim s and one #3977 bearing
onto the #3920 input shaft.
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
1/16"
Slide the second #3977 bearing onto
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 .
Install and center the #2291 dow el pin
i n t o t h e i n p u t s h a f t .
Slide a #2270 drive cup onto the end of
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 : 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 T s p u r g e a r
6 9 2 , q t y 6
4 - 4 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 t o o t h ( s m a l l e r ) s p u r
gear to #2287 tw o speed housing w ith
t h r e e # 6 9 2 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 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 T )
2 2 8 7 6 9 2
6 9 2
6 9 2
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
6 9 2
6 9 2
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 eburr holes edges on #2292 tw o speed shoes
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 .
Add a dab of #6591 lube to the #2289
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 epeat on the second shoe.
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 e w s e q u a l l y !
8
5/64"
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
Slide one #3977 bearing and tw o #2293
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
Slide on one #3977 bearing onto the opposite end of the input
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
Slide #6863 bushing onto the end of the #2276 brake
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
Place #2277 bushing in betw een the brake cam and brake
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   $ 
ttach #2368
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 .
Squeeze four beads of #6591 diff lube equally spaced
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 .
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   & 
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 .
Slide one #2278 brake pad (steel side facing bulkhead ) onto
the #2269 center bulkhead. Slide the second #2278 brake pad
( 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
bulkhead.
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
2368
6924
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 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 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 h t l y s n u
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 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 .
Squeeze four beads of #6591 diff lube equally
spaced apart t o t h e f r o n t s i d e o f t h e r i n e a r
and pinion ear.
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 n t h e # 2 2 6 9 b e a r i n c a p o v e r t h e b e a r i n 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 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 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 t
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
r o n t c h a s s i s b r a c e s ,
l e 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 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 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 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 .
Place #2260 handle onto
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
r o n t / r e a r t o w e r .
Then thread on the #7260 nuts and tighten.
R e p e a t s t e p 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 ( 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 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 r e a s e
inside the #3886 axle hole w here show n, then
o n t h e # 7 3 8 1 c o u p l i n a n d i n s e r t t h e c o u p l i n
i n t o t h e a x l e .
Slide the #3886 axle into the #3888 do bone,
a l i n i n 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 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 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 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 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 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 / 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 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 i n t o t h e
s t e e r i n / 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
s t e e r i n / h u b c a r r i e r s .
F R O N T : Thread a #6273 ball end into the
b o t t o m o f o n e r i h t a n d o n e l e f t s t e e r i n / 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 : Thread a #2257 rear toe ball end into
t h e b o t t o m o f o n e r i h t a n d o n e l e f t s t e e r i n /
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 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
dogbone
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
#7381
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 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 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 / h u b c a r r i e r
l e f t a n d r i h t
3 9 6 5 , q t y 4
b e a r i n 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
( 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 ,
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
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
LR
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
32 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 l y
l e f t r e a r a s s e m 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
gauge can be rem oved.
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
Line up the #2233 front upper suspension arm w ith the inner
h o 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 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 d s i n
t h e h i n g e p i n .
C i p i n t h e t w o # 2 2 3 9 c a s t e r c i p s . P 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 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 i n k
t u r n b u c k e
6 2 7 4 , q t y 4
b a c u p ,
b 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 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 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 c u p s o n t o t h e # 6 2 6 4 t u r n b u c k e u n t i
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 e ) .
A s s e m b e b o t h t u r n b u c k e s .
T w i s t t h e # 2 2 5 1 g r a y b a 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 e u n t i 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 e ) . A s s e m b e b o t h t u r n b u c k e s . T h i s r e s u t s i n 2 °
r e a r t o e .
S n a p a f o u r t u r n b u c k e s i n t o p 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
( 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
1.80"
4 5 . 9 m m
2.02"
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 e o f t u r n b u c k e w i t h n e e d e n o s e p i e r s .
2 . T h r e a d o n b a 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 e
t o o t o f i n i s h .
3 . S q u e e z e t u r n b u c k e o n t o b a e n d w i t h n e e d e n o s e p 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 e
2 2 5 1 , q t y 4
b a 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
( 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 # 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 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 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 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 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 8 , q t y 4
s h o c k c a p
7 1 7 , q t y 4
s h o c k p i v o t b a l l
7 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 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 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 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 # 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
s h o c k p i s t o n #
r e a r
1 : 1
6 4 6 5 , q t y
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 9 9
6 4 6 5 # f r o n t
6 4 6 5 # 2 r e a r
5 4 0 7
7 1 7 p i v o t b a l l
7 1 7 e y e l e t
6 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 r
6 4 7 3 , q t y 4
s h o c k b u s h i n g
3/32"
1 : 1
3 9 5 9 , q t y 4
s h o c k c o l l 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 f t u p n d d o w n
s e v e r l t i m e s t o
l l o w i r b u b b l e s
t o e s c 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 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
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 p b o u t
h l f w y w i t h o i l n d i n s t l l o n t o
t h e b o d y . T r y t o r e t i n s m u c h
o i l s p o s s i b l e d u r i n g s s e m b l y .
T h e s h f t w i l l e x t e n d o u t s y o u
t i g h t e n t h e c p d o w n .
s t e p 4
S E T T I N G T H E
REBOUND
M o v e t h e s h o c k s h f t
i n n d o u t f e w t i m e s
n t h e n p u s h i t l l t h e
w y i n . I t s h o u l d b e
e s y t o p u s h t h e s h 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 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 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 d r o p o f
o i l n d t r y s t e p s
6 - 7 g i n .
I f t h e s h o c k r e b o u n d s t o o
f s t , o r y o u c n n o t p u s h t h e
s h 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 p b o u t
f u l l t u r n n d p u m p o u t s m l l
m o u n t o f o i l b y p u s h i n g t h e
s h f t i n . R e t i g h t e n t h e c p
n d t r y s t e p s 6 - 7 g 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 k 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 r
S l i d e o n e # 3 9 5 9
b l 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 d e d
s h o c k c o l l 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 d o n t h e s h o c k
c o l l r .
T h r e d o n t h e s h o c k
c o l l r . M k e s u r e t h t
t h e s h o u l d e r i s f c i n g
d o w n w h e n t h r e 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 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 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 , n d # 3 9 4 4 g o l d
s p r i n g s o n t h e r e 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 d d t h e
# 6 4 7 5 s p r i n g c u p t o 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 : 3944 gold
6 4 7 5
1 7
3/16"

s t e p 7
F R O N T S H O C K M O U N T I N G
Add the #6473 shock bushing to the
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
bushing and add a #6472 shock
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 e t i n t o t h e
o u t e r h o 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
Add the #6473 shock bushing to the
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
bushing and add #6472 shock nut.
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 e t i n t o t h e
o u t e r h o 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
ride height, see page 30.
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
box into the #2256
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
b a e n d , b 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 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 e s e r v o s p a c e r
m e d ( . 0 8 0 " )
s t e p 1
Push the #7673
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 a c e
a # 5 4 0 7 r e d O -
ring on each
s c r e w .
Set the #7721
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
just enough to
s i g h t 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
around.
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 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
1/16"
1 8
. 0 5 0 " , 1 / 1 6 "
3/16"
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 f i t t i g h t .

I J A F 
Find the appropriate #9180 servo horn for your servo from
the chart at right. Install the #3857 short ball end into the
servo arm. Fasten the servo arm down with the stock
mounting screw that came with your servo. DO NOT POINT
IT STRAIGHT UP! See below for correct angle.
Find the appropriate thick or thin #7336 offset spacer for
your servo from the chart at right. Attach the spacer if any, in
between the #7336 mount and the servo with the #7337
washers and #6917 screws.
Airtronics
94102
Airtronics
94738, 94157, 94158, 94257, 94258, 94357, 94358,
94452, 94453, 94751, 94755
Hitec
HS-5625MG, HS-5645MG, HS-625MG, HS645MG
Hitec
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
Futaba
S3003, S9202, S9101
Futaba
S9404
KO
PS-401, PS-2001, PS-2004, PS-2015, PS-2173, PS-
2174, PS-2123, PS-2143, PS-2144
STEERING SERVO TYPE
#7336
SPACER #9180
SERVO
ARM
no spacer A
thick spacer A
no spacer H
thin spacer H
no spacer J
thin spacer J
no spacer F
thin spacer F
thick spacer F
thin spacer J
1/8" (1.5mm)
3857
7336
offset spacer 7337
9180
7336
servo
mount
face up
face up
6917
7337
7337
stock screw
See Radio Adjustments section of manual for
more info on correctly setting steering linkage.
I J A F  !
Attach the servo to the radio tray with two #6917 screws.
6917
6917
19

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 .
Slide the w ire through #6338 antenna and push the
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
Tw ist #6274 ball cups onto the #3867
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 .
Snap one end of the ball end onto the
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 .
1.59"
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
1/16"