Associated Electrics WORLD'S CAR 6037 User manual

#6037 1:10 SCALE OFF ROAD KIT
INSTRUCTION MANUAL
DO NOT DISCARD THIS MANUAL!
Save for future, hassl e· free re-order in g of parts
Associated Elec tric s, Inc.
3585 CadillacAve.
Costa Mesa, CA 92626

. ~
CHAMPIONSHIP-WINNING
STEALTH TRANNY
NEW REAR
BULKHEAD
UNIVERSAL DOGBONE
REAR AXLES
STRONGER, PRE·MILLED,
HARD ANODIZED
ALUMINUM CHASSIS
NEW YELLOW FRONT & REAR WHEELS -......
WITH PROLINE TIRES & FOAM INSERTS
I

NEW GRAPHITE FRONT & REAR
SHOCK STRUTS
NEW FIBERGLASS BATTERYSTRAP
•
NEW BUSHING
BELLCRANK STEERING
HARD ANODIZED,
TEFLON SEALED SHOCKS
SILICONE SHOCK OIL
NEW STRONGER
SUSPENSION ARMS
CHAMPIONSHIP FEATURES
•

FIRST, A WORD ABOUT
YOURNEWCAR
Your new RC10 W orl d's Ca ri nc l udes all of the new ly
des i gned parts our Team has been using that have helped
us win fourofthe five 1: 10 Off Roa d World Championships
everheld. We fe el there Is no bettercar available.
As great as the existing Team Car has been , we
know we have to continually work at improving our car so
we can stay ahead of our competition. This car will show
you th at we have beenbusyworking on a number of impor·
tan! upgrades. While the ne wcarlookssimilar to the old car,
th e re are many new changes. The new car starts with a
black. hard anodized aluminum chassis
made from a new
ma terial which is stronger th an our original chassis. and h
comes with the bottom ofthe chassis alreadymilled out li ke
our Team uses. It also comes with:
• Graph i te front and rear shock struts
• New , s tronger, suspension arms
• New rear bulkhead wi th ne w adjustment points
• Fiberglass battery strap
• Graphite transmiss ion brace
• New yellow wheels (3 piece fronts with al um i num screws
and one piece 2.175 ' rears) which come with Proline XTR
compound tires with foam Inse rt s
• RC Performance Specialities Turbo M ira ge Lexan body
• N ew bushing bell crank steering
• Silicone shock oil
• 1.02 rear shock sha ft s and suspens i on tr avel limi t ers for
front and rear shocks .
• The ca r also comes wi th our Championship-winning St ealth
t rans miss i on
• Hard anod ized Teflon sealed shocks
• Teflon shock pistons
• Aluminu m inli ne front axles
• 30• caster blocks
• Unive rsal dogbone rear axles
• And morel
BEFORE YOU BEGIN
You will find the photos so easy to follo w that you
may be tempted to put the car togelher from the photos
alone. However. although you have the bes tcar kit, if you
want the best CO M PLETED model race car, then you will
want to put it together correctly by following these instruc-
tions. Allthars required is to read the few linesof text near
ea
ch photo .
Take your tlmeassemblingthecar. It's not a race
to see how fast you put it together; it's how well you put it
together
that determineshow fast you can race . Please note
the steps below before you begin to assemble yourk it.
0 Step 1 OPEN THE PARTS BAGS WHEN THE STEP
SPECIFIES , NOT BEFORE ,otherwi se you will get the parts
m ixe d up and t hen you will have t roub le assemb l ing you r
car. When you open each main bag for the first time,
check the contents against the parts
list supplied as a
separate sheet that came with you r manua l.
All major parts bags are referred to by number In
the ma nual. While build ing the car, you will sometimes be
working with several bags at the same t ime. I nside each
ma jorparts bags there are more bags; these are not num·
bered and be l ong to the bag they came out of .
0 Step 2 KEEP THE PARTS SEP A RATE .While bu ild·
ing the ca ryouwill sometim es be working with several parts
bags at the same time. Bags and parts will start multiplying
like
rabb its as you build. Try not to confuse parts from one
bag with another. A good way to prevent thisis to use large
paperplates(picnicplateswithpartitions are the best). They
will help you separate the parts and they give you enough
area to spread them out in so they will be easier to find .
Mark the plates with the bag numbers before you put the
parts in to th em. W hen the plates are used up you can rela·
bel the plate for another bag.
We ha ve included some miscellaneous spare fas-
teners and clips, so do nnt worry w hen you have parts re-
maining after you ha ve fin is hed.
0 Step 3 CHECK THE SUPPLEMENTARY SHEETS .
Associated isconstantly testing new and improved compo·
nents and then updating the kit with the m when they test
out to be benef ic ial. N ot all updates will benoted In the writ ·
ten manua l ( the manuals cannot be reprint ed to k eep up
with the updates) . So before you begin. check each parts
bag to see If they contain any supplementary in st ru ct ion
sheets. If so , l ocate th e section of the manual where th is
change first app lies and attach the shee t (s) to that section
so yo u will not forget about the changes wh en assembling
the kit.
0 Step 4 ADDITION AL ITEMS NEEDED TO OPER·
A TE THE CAR:
0 2 channel RIC surface ra dio system .
0 Battery pack (6 or 7 cell).
0 Batterycharger (for 6 and/or 7 cell packs).
0 Electronic Speed Control.
0 RIC electric motor.
0 Servo saver ( Assoc .#8435 or #5551, orKim brough equiva-
lent) . Using this item is optional depending upon steering
servo used and your setup preference.
0 Motor pinion gear (48 pitch); si ze will be determined by
type and wind of motor being used .
0 Step 5 TOOLS. Your kit contains the four Allen
w rench es and the turnbuckle/shoc k wrench that you will need
to assemble yourcarkit, butyou will still need the follow ing
too ls:
0 112 Phill ipsscrewdriver(Assoc. #SP-76)
a Needle nose plie rs
a Hobby knife , such as a X-actoO with apointed blade
a Soldering iron ( 40 to 50 watts) and a small amount of
ROS IN (no t acid) core 60/40 solder.
a Super glue (instant adhesive)
pag e 4
a Ruler w it h decimal inches or metric measure
The kit can beassembled faster and easier wi th the
foll owing to ol s:
Sc re wdriver hand leA ll en wrenches fr om A ssoc iated In sizes :

• #6957, .050' • #6956, 1/ 16 ' • #6961, 2.5mm
• #6959, 5/64. • #6960, 3132"
• A 3116' nut driver will make Installing the ball ends and
upper arm turnbuckles easier. (#SP-66)
• A 1/4' nut driver will
make installing the 4-40 nuts easier.
(#SP-65)
•
An 11/32' nut dr i ver will make installing and adjustlng the
8·32 rear axle diff nut easi er . (#SP-82)
• A precision rulerwith decimal inches
or metric measure.
WARNING/ Do not use a powerscrewdriver to in-
stallscrewsIntonylonparts. The rotation speedis too fast,
and causes the screws to heat up when being driven into
plastic
or nylon parts, then strips them out.
0 Step 6 IF DYEING YOUR PARTS. The ny lon parts
in
your kit are made from virgin material, so they can be
dyed according to the followingprecautions:(1)
To keepthe
color consistent on a
ll of the parts, the container should
hold all of the parts at the same time. (2) Use Dylon (true
nylon
or plastic dye) or clothing dyes (liquid or powder) of
yourchosen color.
Follow t he dye company's safety pre-
cautions and Instructions. (3) To preventwarpinganycriti-
cal parts, bolt the transmissi,on case halves togethe r. After
dyeinghas
beencompleted, thecase ha lvescanbeunbolted.
0 Step 7 F INAL NOTES:
(1) Fo r you experienced buildersandracers:please
build the car our way flrstll The ACtO Worlds Car is a
remarkab
ly fast buggy right out of the box. There's a good
reasonfor everythi
ng on thecar,andvery few compromises
were made in its design. If
you build it our wayfirstyou can
see what your car is capable of before you make changes
and you will then have a base pointto compare against.
(2) Put a check mark in the box ( 0 ) at each step
after
you finish it. Then when you stop during assembly, it
will be easier to find where you need to co~tinue from.
(3)
To help you identify certain parts, occasionally
an actual-size drawing will accompany the photo. (See
ex -
ample infig. 2.) You can place your part on topof the draw-
ing to be sure you have picked up the right part. Mostlikely
you will end up with spare parts and fasteners, but this is
nothing to worry, about because we have deliberately left
you with some spare items.
(4) We have used some spec ial abbrev ia tions
througholllthismanualfor the various typesofscrewsused.
Thefollowing listidentifieswhattheabbreviationsstand for:
• FHMScrew: Flat Head Ma chine Screw. Standard thread
screwwhich requires a Phillips screwdriver.
• FHSScrew: Flat Head Socket Screw. Standard thread
screw which requ
ir es a Allen wrench or driver. The same
type
of tool is used for the two following fasteners:
• BHSScrew: Button Head Socket Screw.
• SHCScrew: Socket Head Cap Screw.
(5) In ordertokeep a sense
of direction when build·
lngthecar,
we use thefollowing descriptions to standardi ze
the right and left sides of the vehicle. The driver's side or
leftside: with the driversitting in thedriver'sseat facing the
front
of the car, his left hand is the driver's side. The pas-
senger or right sidewill be the driver's right hand side.
(6)Thefollowing typesofspecial instructions,
in /tal·
ics, will be used throughout the manual:
• Racer's Tip: This is a trick used by some of the Team
drivers to improve their car's handling or performance, or
simplifyits maintenance.
• Note: Alternate ways to assemble the kit, including tips
tor smoothing out difficultassemb/ias.
• WARNING/ This alertsyou to be careful to preventdam-
age to parts or use of wrong parts that may reduce perfor-
mance.
SAVE THIS MANUAL! This
Is more than an In·
structlon manual. ft Is also a handy supplement to the
Team Associated 1:10 scale off road buggy catalog. You
can use the manual photos and descriptions to Identify
part numbers and names to help you order parts. Use
the current catalog for pricing.
....r-~_...,.....,.....,
FRONT END ASSEMBLY
page 5
0 Fig. 1 Read pages four and five entirelybeforepro-
ceeding! We' ll start by removing t he #6309 black anodized
aluminum nose plate from bag #6·4 . It will look like fiQ . 1.
Fig. 1
0 Fig. 2 In bag #6·1 you will find the #6207 front sus·
pension mounts (they are connected by a molding runner)
and six #6280
8·32 x 1/2' alumi num FHMScrews. Fig. 2
shows the left side frontsuspension mount Installed. It also
shows the right mount and the three #6280 screws used to
mount
it to the noseplate.
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#6280
8·32 X 1/2
aluminum Fig. 2
0 Fig. 3 From bag #6-14 remove two #6273 long ball
ends and two #7260 4-40 sma ll thin plain nuts. Now open
bag #6-1 and remove the #6210 front carrier blocks. The
carrierbl ocks areconnected by asmall molded runner which
you must remove with your X-act oC> kn ile. Be sure to re-
move ALL of the runner. Screw one of the #6273 ball ends
into
each carrier block as shown and then thread on the
#7260 thin plain nuts. NOTE: A 3116" nut driver will make
installing the steelballends and sma/14-40 nuts easier.
@
#7260
4-40
thin plain nut rn'lmmm
#6273
~ 4-40
Fig. 3
0 Fig. 4 Go to bag #6·1 again and remove the two
#6221 nyl on steering blocks. Fr om bag #6-14 remove two of
the #62731ong stee l ba ll ends, two #7260 4-40 small pattern
thin plain nuts, and four #6936 #4 aluminum flat washers.
Place two washers onto each steel end and then screw one
ba ll end Into each steeri ng block as shown , and then thread
on the #7260 4- 40 thin plain nut from the back side . Make
sure the balls are mounted on opposi te sides of the steering
blocks so that theyboth will be on top of the steering blocks
when mounted on the car.
#4 flat washer rrllmmrn #6273
@
#6936
al uminum ~
4•40
@
#7260
4-40
th in plain nut
72 60'-
Fig. 4
0 Figs. 5 & 6 Remove the two #6220 al uminum
lnllne front axles from bag #6-1 (fig. 6). Insta ll one axle in
each
#6221 nylon steering blocks (fig. 7), making sure t hat
the hole In each ax le lines up with the hole in the steer i ng
block. The parts should push together with your fingers; if
they don 't, fit a 1/4' nut driver over the threaded end of the
axle and then push the axle Intothe steering bl ock. WA RN-
ING! Threads onthe end of the axleare aluminum and can
be easily damaged by the nut driver. Repeat the process for
the second axle and steering block.
page 6
Fig. 5
Fig. 6
0 Fig. 7 The axle is round and will be fairly ti ght in the
steeringbl ock, so try to a li gn the hole In the #6220 axle with
the hole in the #6221 nylon steeri ng block as you are as-
sembling the parts. WARNING/ Do not use pliers on the
bearing surface of the axle, because this can damage the
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axlesurfacesothat the bearingswill no longerfit. The la rger
diameter of the axle will still
be sticking out of the steering
block slightly; that's ok
ay. Just make sure the holes line up.
Fig. 7
0 Fig. 8 In bag #6·1 you will find two #6223 kingpins.
Th is bag conta insseveral diHerent l ength pins, so match the
pins to the actual-si ze drawi ng below.Check that each ki ng -
pin wi ll go through both steering blocks and axles. If you
don't do
this, Itwill bealmostimpossible to getthe kingp in to
go through the #6210 carrier block and the steeri ng block
and axlewhen weassemble them . Once you have checked
the fitof the kingpins, remove them aga in.
fl
(([t ===:::::J!JI!J #6223 Fig. 8
0 Figs. 9, 1 O, 11 & 12 Take the two #6210
carrierbloc ks and insta ll the steering bl ocks and axles into
ea ch one. Both ball ends will be on the same si de when
installed cor re ctly, and the ra ised side of the angle on the
bottom of the #6210 carrierblock will be away fr om the ba ll
si de . Now re install one of the #6223 kingpins through each
of the ca r rie rblock/axle assemb li es as shown infi gs. 10 and
11 . Try to center the kingpins. Fig . 12 shows a package of
#6
299 1/8'E-c li ps from bag #6-1 . Remove two from the pack-
age and install one on each of the kingpin's two grooves.
N
ow take out two more E-c lips and insta ll them on the other
kingpin.
page 7
\
#62g9
~ e-clip (J(====:JI]D' N6223
1/8shaft ·"
Fig. 9
Fig. 10
6299
'
Fig. 11
6299
Fig. 12
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a Fig. 13 In bag #6·1 you wi ll find two sma ll #6951
4·40 x 1/8' set screws. Locate your #6950 tool bag (which
contains four sizes of Allen wrenches) in the la rge master
parts bag. Take out the smallest Allen wrench (.050') and
install the two set screwsintothe #6221 al uminum front ax·
les. Rotate the steering blocks In the block carri ers so that
you can see the threaded hole on the back side of the front
axle. Using the same Allen wrench,installthe set screw into
the back of the front axle until"tightensdown on the kingpin
as shown in fig. 14. Do the same with the other ax le assem-
b ly .
N6951
m:l setscrew Fig.
13
a Fig. 14 Now remove the two #6206 newbl ack front
suspens ionarms from bag #6-1.They are made of stronger
material. Removing the parts molding runner is harde rt han
before . The best way to remove the runners from the arms
will be to firmly grab the runnerwith a pair of slip joint pliers
where the arm attaches to the runne r, and push down with
the pliers. When the runner breaks free, do the other three
attaching points, then the other A-arm . Now carefully ta ke
your X·actoC knife and trim the ends to r emove any of the
re maining runner so tha t it will not interfere with sus pensi on
travel.
6206
\
remove~
Fig. 14
a Fig. 15 Nowremove the two #62. 26 front inner hinge
pins and four 6299 1/8' E-clips from bag #6·1. Slip one of
the hinge pins into each end of the front suspension arm to
chec ·k the pin fi t. The A-arm should be able to swing freely
on the pin. Racer 's tip: Most racers keep a .126' straight
reamer in theirtool
box to free up the suspension arm pin
holesandto clean themafterracing. We DO want the pin to
f it tightly in t he #6207 front suspension mou nts.
Line up one of the #6206 front A-arms with the left
han d f ro nt suspension mount. Now push one of the #6226
front inner h in ge pins through the front of thearm, the mount
and then the back ofthe arm as shown. Use a sma ll screw-
driver to push an E-clip into each grove of the hinge pin.
Repeat the proc ess for the right side suspension arm.
c..
6299 6226
6299 }
#6299
~ e-clip l![=====:mm #6226 Fig. 15
1/8 shaft
page 8
0 Fig. 16 Remove two #6227 front outer hinge p ins
and fou r#6299 1 /8' E-clips from bag #6 -1. Now take theleft
hand steering block and carrierassembly from fig . 10. Line
upthe le ft hand carrier/s tee ringblockassembly between the
outer holes on the lefthand front suspension arm . Install the
hinge pin t hrough the arm and carrier block. Now inst a ll an
E·clip in to each groove of the pin. Do the same for the right
hand parts.
6299
#6299
~ e-clip 1[1 ===::Jilllh 6227 Fig. 16
118 shaft

0 Fig. 17 In bag #6-1 you will find the #6232 new
graphite front shock strut . From bag #6-14 remove two 116270
short steel ball ends and two #7260 small 4-40 plain nuts.
Thread the ball ends into
the graphite shock strut (see fig.
t8 ) and then thread the pl ain nutsonto the ball ends.
0-1-C! #6270
~....-'-' 4-40 @
117260
4-40
thin plain nut
Fig. 17
Q Figs.18 & 19 Frombagt6-10removetwoll6927
4-40 x3/4' SHCScrews,
two 116936 #4 aluminum washers,
and two #6295 4-40plain nuts. Then !rom bag #6·1 remove
two #6925 4·40 x 112" SHCScrews. Thread the two #6927
4·40x 3/ 4' SHCScrewsinto themiddle ol the three hol es on
the top olthe shock strut.The headsolthese screws will be
on the same side as the #6270 steel ball ends. Slip the
washe rthen thenut on the screw.Nowdo the second screw .
Now line up the grapMe shock strut with the back side ol
the front suspension mounts as shown . Fasten th e shock
strut to the116207 mountsusing the two t6925 SHCScrews .
6936 6927
'
•
6295
QUHI!I!I,!I!Ii!U!D #690 27 3/
4·4 X 4
p #6936
~ #4 llatwasher
aluminum
Fig. 18
;;:0. #6295
~ 4-40plain nut
page 9
6925
Fig. 19
0 Fig. 20 In bag 116-1 you will find two #6262 1. 65"
longturnbucklesand and inbag #6-14 the 11627 4 plasticball
end cap molded tree. Remove lour or the plastic ball end
caps and thread them onto the two turnbuckles. The plastic
ball
end capson both endswilllace the same direction.Note:
Each lumbuckle rodhas right hand threads on oneend and
left hand threads on the other. so the plastic endcaps wf/1
thread on In opposite directions on each end.
Make sureyou threadon the #6274 plastic ball ends
evenly so that you will have maximum adjustment range .
Adjust yourplastic ball ends until they are 2.14' (29/64'
or
54. 40mm) from the centerof the ball end hole to the center
of the otherball end hole. Note: If you overtighten the plas·
tic ball encl caps onto the turnbuckles.you willpush the tum·
buckles into the ballendholesendtheplasticballend caps
wlff be damaged beyond repair. This turnbuckle measure -
ment, al ong with a ll of the other turnbuckle measurements
still
to come, are justprelimina ry measurements. We will fine
tune the adjustmentsatthe end or the Instruction manual.
6262 6274
I~ 2.14" - -1
1--- 2 9/64' ---1
54.40mm
ll!lll!IIIJII!r l.l.r) I •!Ill Ill\! !1!11 1 ~~
6
2
5
~2 Fig. 20
Cl IQ jJ6274 (S ee figure on nextpage.)
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1t== r,..__; ;:-llllli{d 2.14 1lliiillllil . _ ~ --l/
Cb j mmmm l mllllllll!i( 0
(dimension for fig. 20)
0 Fig. 21 Snap the plastic turnbuckle ball ends onto
the steel ball end on the top of the left hand #6210 front
carrier block, and on the steelball end on the left hand of the
shock strut. You will probably have to use your need l enose
p lie rs to snap them on. Now go ahead and do the same for
the right hand turnbuckle assembly.
. ...
~.
Fig. 21
0 Fig. 22 The turnbuckle lie rods can be easily re·
mov ed by carefully holding the plastic ball end with your
needlenose pliers (next to the ball) and twisting the plastic
rod end offof the stee lball.
Fig. 22
0 Figs. 23, 24 & 25 Nowwe'll al1ach the #6309
noseplate assembly to the new #6302 blackhard anodized
aluminum chassis. You wm see that your chassis (fig. 23)
has alreadybeen mft!ed the same as used by our Team driv-
ers . In bag #6 -2 you will find one #6280 8·32 x 112· alumi -
num FHMScrew, one #6281 8-32 x 7/8. aluminum
FHMScrew. In bag #6 -4 you will find one #6931 8-32 x 114•
steel FHMScrew
{1) Looking from the back of the chassis (fig. 24),
Insert the #6280 screw into theleft, the #6931 screw In to the
midd l e, and the #6281 screwinto the right. (2) Now s lide the
nose plate ove rthechassis as shown In fig. 24, aligning the
ho l es with the screws . (3) N ow thread them Into the nose
plate until t hey are as in fig. 25.
f'rmmmrn #6280
!)ILWJilWI 8·32 X 1/2
aluminum
6931
lmm #6931
[)lllll 8·32 X 1/4
steel
6302
Fig. 23
Fig. 24
page 10

Fig. 25
0 Fig. 26 Now go back to bag #6-2 and remove the
four #6253 1/4' x 318' flanged bronze bushings, and two
116254 nylon bell cr ank steeringarmswith theirnylonsleeve
nutInserts.
Note: Yourproduction#6254 bellcranksteering
partswill
be white, not black, as showninthe photos. Press
one of the #6253 bronze
b~shings into each side of the two
steering arms.
Note: #6252 is a complete bell cranksteer-
ing replacement kit.
6254
©0#6253
1/4X3/8
flanged bushing
6253
Fig. 26
0 Fig. 27 In bag #6-14 you will find five #6270 short
steelballends.Thread theball endsintothe bellcrank steer-
Ingarmsas shown.
No nuts are needed for theseballends.
11-ffrn, ~70
'-"iF" 4-40
6270
Fig. 27
page 11
0 Fig. 28 Remove the two #6263 2.06" length tum-
buckles andone #6260 1.0' turnbuckle from bag #6-2. Now
remove
six of t he #6274 plastic ball end caps from bag #6·
14 andthread themevenlyontotheturnbuc·kles.Theplastic
ball endcaps will all face thesame way on these turnbuck-
les. Adjust the length
of the small turnbuckle from cen-
ter of ball hole to center of ba ll hole to 1.47' (1 15/32" or
37.5mm). Then adjust the two longer steering lumbuckles
to 2.
51' (2 1/2" or 63.75mm) center to center length.
di-J---~ ~ -~~~-m-n-m-mu~-
5
;1;11-II _ III _ III_II_IU_!I---t~
#6274 #6263 #6274
Fig. 28
c!J
#6274
1.47' - - -li
lun l ml 6
#6260 #6274 OIIIIIIIIIIOIIIIIHIIIII
~~~
60
0 Fig. 29 Take theshort turnbuckle tie rod and snap it
onto the bell crank steering arms
as shown. You may need
to use pliers.
Fig. 29
0 Fig. 30 (1) Install the #6254 bell crank steering as-
semblyloosely over the two aluminumscrewsthat are hold-
Ing the nose plate to the chassis. (2) Next, thread the two
#6254 nylon sleeve Insertnuts (fromfig. 26}
on to the #6280
and #6281 aluminum screws. N ote: The sleeve nut is not
threaded,
so you will be making your own threads as you
go. (3} Now go ahead and thread the right hand sleeve nut
onto the #6281 screw. Make sure it lines up and slides in-
side the bushings of the right hand bell cr ank steering arm
as it goes
do w n. (4) Then-lightly tighten it against the nose
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plate and then back the sleeve nut off 1/4 of a tum. (5) Do
the same for the left hand sleeve insert nut and bell crank
steeringarm.(6) Nowcheck themovement
of the bellcrank
steering. It should move back
and forth smoothly with no
binding. If the steering Is still binding, you can back off the
sleevenutsa llnlemoreto free upthesteering. Justdon't go
too far or nwill get sloppy. WARNING/ This isa non-servo
saversteering system. Your servo mayrequire the use ofa
servo saver. This w/11 bediscussedduringthesteeringservo
Installation. section. Racar'a Tip: You can replace the four
#6253 bushings with four #897 114 x 318" flanged ball bear·
lngs for reduced malnlenance, but you will need a #6254
bearing spacer on top to make up the difference In height
be tw eenbushings and bearings.
Fig. 30
0 Figs. 31 & 32 Now go ahead and install one of
the #6263 steering turnbuckles assembled in fig. 28 onto
the right hand sidesteel ballends onthe #6221 nylon sleer-
ing arms, and on the M6254 nylon bell crank arms (fig. 31).
Do the left hand side. In bag #6·5 remove the #6330 body
mount.
Thread this ontothedriver'sright side screw as shown
in fig. 32 .
Fig. 31
Fig. 32
0 Figs. 33 & 34 1n bag #6·4 you will lind two #63 21
blackanodized nosebrace tubes andfour #6288 4-40x1/4"
BHSScrews.One end of each nose bracetube has atapped
hole
through the side, and the tube Itself Is tapped at the
otherend.There aretwo holesInthe front ofthenose plate;
insert two of the #6288 BHSScrews and then thread them
into the tapped end of the nose brace tube. Do not com-
pletelytighten these screws just yet. Now using the two re-
maining #6288 screws, mount the nose brace tubes to the
chassis sides as shown in fig . 34 . Once all four screwsare
threaded
on, you can goback and tighten them.
r
(k, . 16288
IJ"'""' 4-40X 1/4
6321
~8
...
Fig. 33
Fig. 34
page 12

STEALTH TRANSMISSION
AS SEMBLY
We feel this transmission is the best in the world.
Our Stealth transmission
has been responsible for three of
our four IFMAR 1:10 Off
Road World Championship wins
plus
ten NationalTitle wins in buggy and truck. 1993proved
to be one ofour bestyears, with Brian Kinwald winning the
IF MAR Off Road Worlds in Basildon, England; the 1993
ROAR 2WD Modified Nationals in Fountain Va ll ey, CA; and
the 1993 ROAR Truck Nationals in Gr and Rapids, MI . Your
new car has this same race-proven transmission. We know
thiscombination willalsohelpyou greatlyimprove yourper-
formance, depending,ofcourse, on howwell you assemble
and maintain yourtransmission. Sotake yourtime and as·
semble it to the best ofyourability.
Note: Th11 Stealth transmission uses fint~ly Mgl·
neered matt~rials. No lubrication is required exoopt where
inrf!Cated . Using oils or similar lubricants inside the trans-
mission can reduce Itsperformance or cause parts failure.
Excessivelylubricating the ballbearingsin the transmission
case or diffassembly can cause the same problems.
0 Figs. 35 , 36 & 37 Open the Stealth transmis·
slon bag and locate bag A (the dill assembly). (1) From bag
A
remove the #6580 dill gear and the bag containing the
twelve #6581 3/32"carbide dill ba ll s. These are the largerol
the two ball sizes. These carbide balls are the best avail·
able.They will outlast the diffdrive rings atleast ten times (If
the dill Is keptclean and lubed).
WARNING/ NEVER replace these balls with any
other balls except our 16581 carbide dlff balls , for our
tolerances are tighter than most other suppliers '. Due
to tight tolerances and careful packag ing of matched
balls, when replacing
lost or worn 3132" dlff balls, you
MUSTreplace ALL 3132"b alls altha same I/ me withnew
balls from the same package. This means you cannot
even
mix balls from two separate 16581 packages.
(2) Look atthe centerhole of the #6580 dillgear; if
there
Is any flash Inside the ho l e, then you will need to re·
move it.Carefully trim any excess flash from the centerbear·
ing hole with the very tip of your X·acto© knife (the tip will
turn easiest when removing the flash) to make sure you do
not
remove any ofthe gear itself.
(3) From the Stealth transmission bag remove the
#6591 Stealth white silicone diff lube. Another word of cau·
tion. 00 NOT substitute any other type of diff lube on the
balls. Ittookuscountlesshoursoftesting to find the correct
s ifJCOne dill lube to make the dill worl< correctly. Do yourself
a favor: use what comes in this kit!
(4) All the twelve ball holes in the diff gear with
Stealth white silicone dlff lube and then (5) push the twelve
#6581 3132" balls into the holes. (6) Wipe the excess lube
back
In to the ball holeswith your finger. Fig. 37shows your
completed
gear. (7) Carefully clean all of the silicone diff
lube'
from you r hands.
6580
STEALTH
DIFF LUBE
tt6591
-
Fig. 36
6581
Fig. 35
Fig. 37
0 Figs. 38 & 39 Next open bag B which came
I rom the Stealth transmission bag. In thisbag you will find a
total of eight bearings and one bushing. Take out the two
smallest #6589 bearings. These have an outside diameter
of
5116" and an inside diameter of 5132". Place one inside
the center hole of the #6580 dill gear as shown in fig. 39.
Set the second 16589 bearing aside, because we wm be
using itshortly.
8588
cr
8589 0 0
~©
8908
Fig. 38
page 13

Fig. 39
@
116589
5/32X !'J16
unflanged bearing
0 Fig. 40 In bagAyou will find the #6 575 T-nu t and dlff
thrust boltcoveras shown in f ig. 40.R em ove theT-nut (wh i ch
has a steel Insert molded Into it) from the nylon runner.
WARN I NG / Make certain thatyou do notcutoff the •aars•
on the T-nut or the thrust boltcover. Trim the dill thrust bolt
coveroffthe same moldi ng tree and setitaside. We will use
itin fig. n.
Do notcut the •ears•off the T-nut
(NOTACTUAL SI ZE)
Fig. 40
0 Figs. 41, 42 & 43 Also in bag A you w il l find
t he #6578 left diff outdrive hub and the #6 582 diff thrust
spring. Make aure that the
116578 leftdrive hub Ia clean
and free
of all burrs and residue on the Inside an d out·
side. Carelu ll y insta. ll the springinto the le ft diffdrive hub; it
shou ld go in with only a slight amoun t of pressure to the
bottom of the slot. Now align the #6575 nylon T·nut (from
the last step) with the slots in the #6578 left diff hub, and
pushin the T·nut until itcontacts the spring ,steel inset end
first. WARNING/ Donot mi x up the 16582 diffthrust spring
with the 16587 torque controlspring in bag E (this spring
has a slightly largeroutside diameter) that is used
Jatar In
the manual.
There should nowbe approximatelya
3132' (.100')
ga p where shown In fig. 42. Fi g. 43 s ho ws an end view of
th e leftdilf drive hu b a ft erT·nut and spring are install ed.
6575
•
~
6582 7668
Fig. 41
3 / 32" ---~ .... .--. 100
Fig. 42
Fig. 43
0 Fig. 44 Take your X·actoO knife and trim off any of
the plasticT·nut that extends outside of the slots in the ou t·
drivehubas shown .This is necessary so thatitwillfit through
the bearing when we Install It in the case later on.
Fig. 44
p age 14
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0 Figs. 45 In bagAyou will find a littlebag containing
the six smaller#6574 5164' precision thrust baUs.ln another
littlebag
you will find the #6575 2·56x 1' dillthrust boH and
the two .6573dill thrust washers. WARNING/ NEVER re-
place your thrust bells with any other bells except our
16574 thrust bells. Our tolerances are tighter then most
other co mpsnys '. Due to these tight tolerances end care-
ful packaging of matched bells, when replacing lost or
worn5164" thrust balls , you MUSTreplace ALL 5164" balls
at the same time w ith new bells from thesamepackage.
This means you cannot even mix balls from two sepa·
rete 1657 4 packeges.
6573
6575
I
@t6573 Fig. 45
0 Figs. 46 & 47 Slip the two #6573 diff thrus t
washers onto the #6575 dill thru st bo lt as sh own . Locate
your containter of #6588 black grease In the Stealth bag.
Now place a small amount between the two #6573 thrust
washers
Oust enough to hold the sixballs inplace). W ARN·
lNG/ Do no t use the #6591 Stealth dlff tube on these balls .
Fig. 46
BLACK
GRioAS E
#6 588
•
-Fig.
47
0 Fig. 48 Now place the six #6574 thru st balls be·
tween t he two #6573thrust washers ( th ebl ack grease shou ld
hold the m In place f or you). Note : Make sure you have all
sixballsInstalledbetween the washers, becausemorebells
will
cause theclifftoloosenup end lesscancause the thrust
washers to crack.
Cliff Lett 's Racer 's Tip: 'Installing the differential
thrust bearing assemblycan be a pain, but try it this way:
slideone of thethrustwashersontothescrewandputsome
blackgrease on thewasher. Putallsixthrustballsinastraight
line tn one of the lines on the palm of your hand. Hold the
threadedend of thescrewandroll thegreasedwasheralong
the row of balls, picking up theballs one at a lime untilthsy
are stuck to the washerIn a nest circle. Installthe second
washeronto the screw.•
Fig. 48
0 Figs. 49 & 50 Nowtakethe#65nrightdilldrive
hub and one #6579 dilldrive ring from bag A. Also take the
second #6589 5/32' x5/16'unflangedball bearing from bag
B. Make sure that the #6Sn right dlff hub Is clean and
free of all bu r rs and residue on the Inside and outalde.
(Fig .49 shows both parts that wi ll go on the #6577 right dill
hub and fig. 50showsbothpartsInstalled). The #6589 bear·
lngwill go In side thecavity In the #6577 right dill hub. They
should just push in with your linger. Never force them lnl
Now place the #6579 dill drive ring onto the right diff hub.
Race r's Tip: ·The Team driversalways check the diff drive
rings tor thesidethat is moraroundedontheedge and place
thissideagainstthehub. This allows thecliffto workbetter.
You r completed hub assembly should look like fig .
50. DO NOT try to pin the drive ring to the hub. This hub Is
designedtolock the drive ring with out pinning. Leave AS IS.
7667
7tl· 6589
Fig. 49
@
16589
5/32 X 5116
unflanged bearing
Fig. 50
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0 Fig. 51 Locate your 5164" Allen wrench from your
#695Q tool bag . Now slip the long end Into the head of the
#6575 dillthrust bolt. You are going to Insert the whole as·
sembly Into the center of the #65n right dill hub, as shown.
Fig. 51
0 Fig. 52 With theAllenwrench still In the dillbolt, tum
the hub assembly upright so that the wrench Is on the bot·
tom. Make sure that the #6579 dill drive ring is still on and
centered . Now pick up the #6580 diff drive gear (wi th the
balls and bearing still installed) and slipitover the #6575 diff
thrust boltonto
the drive ring and hub.
Fig. 52
0 Fig. 53 Now take the second #6579 diff drive ring
from bagA and put it on top of the dillgearover the dillballs
andcenter it
as best as you can. Remember, If you are do·
ing the racer's setup, the rounded side will be up. WARN·
lNG/ If you remove the gearat any time before you com-
pletely assemble the dlff halves, always double check to
make sure you do not have both drive rings on the same
side.
This can beeasy to do becauseone of the drive rings
maystick
to the diffgearand the othercouldbestuck to the
diffoutdrive hub on the sameside.
Fig. 53
0 Fig. 54 /';low we are going to install the #65781eft dill
drive hub assembly over the #6575 dill bolt until it seats on
the #6579 di ll drive ring. IT IS VERY IMPORTANT that you
make sure th at th ehub centers on the diff drive ring.
Fig. 54
a Figs. 55 & 56 Tighten the diffbollusing theAJien
wrench , making sure that the hubs and dill drive rings stay
centered. Now tum the dill assembly sideways, as shown,
and tighten the di ll screw until the springcollapses fully and
the screw bottoms out. DO NOT O VERTIGHTEN I Correct
adjustment Is bottoming out the spring and bolt and then
backing offthe screw 118 to 1/4 of a tum.
page 16

As you aretightening the diff bolt, you willnotice the
ears on
the T-nut (m arl«ld by the arrow) moving closer and
closer to thebottom olthe slotin thediffhub.Thespring and
diff bolt should bottom outatabout the same timeas the T-
nut ear reaches the bottom ol the slot, but if not, just make
sure you bottom outthe spring and bolt. Once you !eel the
spring
and bolt bottom out, then you can back off the bolt
1/8 to 1/4 of a tum.
Your dlff should operate very smooth ly when tu rn-
ing the hubs In oppositedirections. (Smooth lydoesnot mean
'free spinning", The parts will feel firmly held together but
the mo tion will feel smooth, not rough .) After you have run
thecar once, recheck the dillsetting.Thereisnevera need
to adjust the diff in anyotherway.
Fig. 55
Fig. 56
0 Fig. 57 Open bag Cand remove the 1165651eft and
right transmission casehalves. Make surethat you remove
any flashing from the case halves. Now go back to bag B
and remove four 116906 3/16"x 3/8' unflanged bearings and
two #6903 3/8' x 518 ' sealed unflanged bearings. Insta ll the
four #6906 bearings in the four sma ll cavi ties and the two
#6903 bearingsin thelargercavities inside the case halves
as sho wn.
6906
RH
@
116906
3/8 X 3/16
unflanged bearing
©#6903
3/8 X 5/8
unflanged bearing
LH
Fig. 57
0 Figs. 58 & 59 Open bag 0 and remove the
#6571 drivegearassembly. Carefully deburr the rollpin hole
In the drive gear so the holeisnotblocked andthere are no
raised edges around the hole. Checkbothsides of the hole.
We are doing this to make sure the roll pin will fit and that
the bearing will slide on the shaft. Now take the #6571 drive
gear
and Insert the shaft through the upper bearing ol the
ri ght case half so that the shaft is to the ou tside and the
gear Is Inside against the beari ng as shown in f ig. 59 .
,
Fig. 58
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Fig. 59
0 Figs. 60 & 61 Open bag E and rem ove the
#6572 1/16'rollpin.
Now usinga pairofneedle nose pliers,
squeeze the roll pin into the hole in the #6571 drive sha
ft
and center the pin. You may need to squeeze the roll pin
sllg)!ttyto get it started In the ho le.
Fig. 61
0 Figs. 62 & 63 Install the assembled diffintothe
right case half lowerbearing
as shown in fig. 60. Make sure
that you install the diffbolt head side through the rightcase
half.
Note : If you install the bolt head so that it is on the
driver 's side of the transmission, you may have a problem
with the
dlff backing off. Locate t he #6570 idl er gear and
shaft from bag D
and install it into the centerbearing of the
right casehalf.There
is no right and left gear side, so " can
go in eitherway.
Fig. 63
page 18

•
0 Fig. 64 Take th eleft hand caseha lf and Installitover
the gears, making surethat each gear flts correctlyintothe
appropriate bearing. Now open bag F
and ta keoutlhe four
#6935 4-40 x 1' aluminum SHCScrews . Thread them into
lhe four bolt hole locations on the left hand case . Screw in
the bolts so that they extend about1/8' out or theright hand
case half.
16935
o ~,~~~'~ llil!\lllli\i\11\\l\\\il\i\1 4·40 x 1
aluminum
Fig . 64
0 Fig s. 65 & 66 Back In bag C you will find four
#6569 mo torpl ate spacers, and one case dust end cap on a
small molded parts tree. Remove thelive parts from the t ree.
Now set the end cap aside; we will use II In a few moments.
In bag F you will find the #6566 felt dust sea l. Carefully re-
move the cutouts from the felt seal so that we can install
three of the #6569 motor plate spacers Into the appropriate
holes
as shown. Install the spacers so that the small ends
will go Into the caseholes on theright casehalf as shown in
fig. 66. Install
the #6566 felt seal and spa c ers over the drive
shaft
and onto the case as shown. The spacers wi ll also be
goi
ng over the threaded ends of the four #6935 alumi num
case screws . Now install the rema ining motor plate spacer
in
the fourth case holeas shown .
6569
I
Fig. 65
Fig. 66
0 Figs. 67 Now take the #6604blackanodi zed moto r
mounting plate from the Stealth main bag. Secure It to the
right hand tranny case on themotorplate spacers us i ng the
#6935 screws already installed in the left case half. 11ghten
all fourbolts. WARNING ! These arealum inu mscrews, so
make sure all four screw threads are starled Into the
motor platebefore you beg in to tlglftenthe scre w s. A IU·
mlnum sc rew s can strip their threads veryeasily.
Fi g. 67
Q Figs. 68 & 69 Now take the #6569 case dust
end cap that we set as ideinfig.64 andinstallil inlheholeof
the left case halfasshown in these photos. The locat ion is
indicated
by the arrows.
6604
Fig. 68
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Fig. 69
0 Figs. 70 & 71 Now we are going to start assem·
bling the Associated Torque Control assemb ly. From bag E
remove the 116583 innertorque control hub (with the sloton
the
back side as shownIn fig. 70) .Slide the innerclutch hub
overthegearshaftsothatthehub af~gns with and then slides
over
the drive shaft roll pin, as shown in fig . 71 .
Fig. 70
6 583-...
I Fig.
71
0 Figs. 72 & 73 Bag F also contains the 16584
outer Assoc iated Torque Control Huband the #6585 Rulon
clutch disk. Remove these and tum the outer clutch hub
upsidedown as shownIn fig . 72. Now installthe #6585 Ru ·
lon clutch di sk ontothe inside of the #6584 outerclutch hub
as shown in fig . 73. Ma . ke sure that th e disk is centered on
the clutch hub.
6585 6584
Fig. 72
Fig. 73
0 Fig. 74 Fig. 74 shows the order In which the main
portion of the torque clutch parts will be placedon the drive
shaft as we put the clutch together. (1) Locate the #6596
3116 " x 51 16 " bushing from Bag B. ryve have replaced the
bearing we previously used in this location with a bushing
because ourtestshave shown that the bushing adually wo<ks
better .) Note: This bushing Is pre-oiled through a special
manufacturing process, so no oil is needed during
assem-
bly. (2)Install th e #6596 bushinginside theholeofthe #6584
outerclutch hub.
(3)
Next, install the clutch hub wi th the bushing and
clutch diskonto the gearshaft, the clutch disk still centered
on the hub. Make su re that the bushing goes onto the larger
portion
of the gearshaft and that it Is s li ghtly bel ow the sur·
laceofthe clutch
hub when properly In stalled.
(4) From bag E remove the #6594 thrust bushing
and two thru st bushing washers. You can also re m ove the
#6587 torque control spring and #6629 gold colored 5-40
l ocknut at this ti me .Note:Associated's #6687 contains both
the torque clutch spring and one 116629 gold 5-40 locknut.
(5) Take one of the thrust beari ng washers and slide it onto
the driveshaft.(6)Nowinstall the bronze thrust buJ>hing and
the second steel thnust bushing washer. WARNING / Don 't
mix up the specialhardenedsteelthrust washers from
bag
E with anyother washers . Us ing anyotherwashersfrom the
kitwillpossiblyruin the clutchassembly or thrust bearing.
(7) N ow install the #6587 torque controlspring and
#6629 gold co lo red 5·40 locknut. (8) Tlghten the nut un til
about 1/2 of one thread isshowing outside the nut. This is a
good starting point for the clutch adjustment unlll we fine
tune the transmiss i on l ater.
Cli ff Lett's Racer's Tip: "Like any other spring, a
newslipperspring will
~ake a ser afteruse. This mean sthat
It will be slightly shorter after being fully collapsed, but its
rate will be the same. You can bypass the change problem
by collapsing the spring a couple
of times yoiJrse/1 with a
pa ir of pliers.·
page 20
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