nxt A-0810 A-0820 User manual

A-0810
A-0820
A-0830
NXT GasTruck Kit with Bushings/Bearin gs
NXT Racer GasTruck Kit with Bearings
NXT Graphite Plus GasTru
ck Kit with Bearings
OWNER•&
MANUAL
~ Carefully read throu gh all in structions to familiarize y ours elf with the parts, construction,
tuning tips, and techniques ou tlined in this manual. Being able to grasp the ove rall design
of your NXT 1/ 10 -scale gas- pow ered truck be fore co nstruction will ens ur e a s mooth
asse mb ly.
C1E Take your time and pay close att ention to detaiL Keep thi s manual for future refe ren ce.
TEAM LOSI, INC., CHINO, CA 91710 PIN aoo-o123
MA DE INTHE UNITED STATES OF AMERICA
scan courtesy of Vintagelos i. com

WELCOME NXT OWNER!
Thank you for choosing the NXT truck as your vehicle to enjoy the exciting world of gas· powered, all- terrain racing. The · xr is the
result of hundreds of hours worth of computer-aided design and on-track testing by our engineers and development team . Needless
to say, you will soon come to appreciate that the NXT represents the latest in technolog} and meets the unique demand s of gas·
powered, oiT-road racing.
Since gas-powered models te nd to r equire greater mechanical and tuning ability, il is i mportant that you read through this manua l
co mpletely bef01e beginning assembl y. A little ext ra ti me now will save building time und help get your oe'" truck running sooner.
You
wi ll fi nd that our un i qu e bag-by- bag assembly is bo th q ui ck and easy to fo ll ow. You will also notice that we h ave included a
separate
lip section along w ith helpf ul hints t hro ughout th is manua l to help you tune your NXT and maxin1ize your enjoyment of this
ki t.
Once again, thank yo u for making a wise choi ce ... the NXT.
TEAM LOSI
1. INTRODUCTION
NXT COMPLETED KIT DIMENSIONS
Front Width: 12-3/4 " Rear Width: 12-3/4" Height: 6"
Length: 16-112"
Wheel base: 11-l/4" All dimensions at ride height. Weight will vary depending on accessories.
NOTES & SYMBOLS USED
'it.!' iii'
Thi 10 is a co mmon figure n um ber fow1d nl the beginning of
each ne'' illustration thro u ghout the manual.
0 tep I. Each s tep throughout the entire manual has a check
box to
the len of it. As you co mpleteeach step, mark the box with
a check.
lf vou ne ed to take a br eak and return to building at a
later
um e you will be able to locate the exact s tep where you left
off.
•NOTE: This is a common note. It is used to call attmtion to specific
detailr of a ttrtain step in the as se mb ly.
& IMPORTANT NOTE: Even if yo u are fam il i ar with
Tean1 Losi kits,
be sw·e a nd pay at t ention to these notes. They
point out very importa nt details during the assembly process. Do
not ignore these notes!
>-<> This wren ch designates a performance lip. These tips
are not necessary, but can improve the performance of y our
i\lXT truck.
In il lustrations wh ere it is important to note which
direction parts are pointing,a helm et like this one w ill be included
in
the illustration. The hel met 'vill always f ace the fr ont of the c ar .
Any reference to the rig ht or l eft s id e w il l re late to the direction of
the helmeL
KIT/MANUAL ORGANIZATION
cun·ent st eps can be illustrat ed m ore clearl y.
For your conven ience, an actual size hnrdwar e identification
guide is included with each step. To check a part , ho ld il against
the silhouette until t he correct part is identified. ln so me cast!~
extra hardware has been supplied for parts tha t ma y be easy to
lose.
The
molded parts in the NXT are manufactured to demand-
ing tolerances. When screws are tightened to the point of be i ng
snug, the parts are held flfiTIJ y in place. For this reason it is very
in1portant that screws not be overtightened in any of the plastic
parts.
To i
nsure th at parts are no t lost during construction, it is rec-
o mm en ded that you work over a towel or mat to prevent parts
fr om ro ll ing away.
IMPORTANT SAFETY NOTES
I. Se lect an area for assembly that is away from the reach of
small children. 17te paris in tile kit are smalland ca n be swallowed by
children , c ausing choki11g and possihle internal illjury.
2. The shock fluid and greases supplied s hould be kept out of
children's rea ch. Thty were not intended for human consump tion!
3. Extrcise care when using an:; hand tools. s harp instruments,
or power tools during construction.
4.
Corejitlly read allmanufactum:f wamings ond c autions for an y
glues, f
ue l, or paints tha t may be used for assembly and operating
pur poses.
5. Cas powered vehicles should not be operated indoors.
6. Be careful when handling y our truck afier it has been run
for any period of time . The engine and man y parts can get ex-
tremely hot during operation.
The NXT kit is composed of diiTerent bags marked A through F.
Each bag con tains aU of the partsnecessary to co mplete a particu-
lar section of the J~,"XT truck. Some of these bags hav e subassem-
bl y bags within them. It isessential that you open only one bag at TOOLS REQUIRED
a time and follow the correct sequence, otherwise you may face Team Losi has supplied all Allen wrenches and a special wrench
difficulties in finding the rig ht par t. It is helpful to read through that is needed for assembly and adjustments. The following com -
the instructions for an entire ba g pri or to starting asse mb l y. K ey mon tools wi ll also be required: Small natb l ade sc rewdriver ,
numbers (in pare ntheses) h ave bee n assigned to each part an d Phillips scr ewd r iver , need le nose pliers, regular pliers, scissors, or
remain the same t hr oug hout the manua l. In some ill us tr a ti ons, ot h er body cutt i ng /trimming tools. 3/16", 1/4". 5/ 16", and 3/8"
parts which have alr ea dy b ee n installed are not sh own so that th e nut drivers are optiona l.
i

RADIO/ELECTRICAL
A suggested radio layout is pro vided in this manual. Your high perf ormance RIC center should be consulted regardingspecifics on
radio/electrical e quipment .
HARDWARE IDENTIFICATION
When in question, use the hardware identification guide in each step. For screws, the prefix number d es ignates the screw s iz e and
number of threads per inch (i.e., 4·40 is 41'4 screw with 40 threads per inch of length). The fraction fo ll owing designates the length of
the threads for c ap head screws, and the overall length for flathead scre ws. Bearings and bushings are referenced by the inside
diameter x outside diameter. Shafts
and pins are diameter x length. Wa shers are described by inside diameter or the screwsize that
wi ll pass through the inside diameter. E- el ips are sized by the s ha ft diameter that they arc attached t o.
FUEL
Th e fu el used to power the NXT truck is a special blend of oils and nitro. Thisfuel is highly fl ammabl e and should be treated as such.
Be s
ur e to read any warnings and ca utions that ma y appear on the packaging of the fuel. Becau se of the e xhaust fumes that are
produced from nmning any gas·powered vehicle, the NXT shOldd not be operated indoors. Be careful when handling your truck
while the engine is runnin
g. Th e exhaust f um es from the tuned pipe can cause irritation and btu·ni•'S of the eyes. Never point the
exhaust pipe
wwa rds yo ur fac e. I know this sounds stupid, but w e'v e a ll had it happen to us and it really isn't a pleasant experience.
Th ere ar e several differem brand s of fuel ava il able for the gas ·powered engines. We have found that the O'Donnel and Blue
Thunder fuels are more reliable and perform better than the other s. It is not recommended that you usc a model airplane or model
helicopter
fu el in yo ur N XT truck. The fuels for model airplanes and helicopters do not have the pr oper rypes. or content of oil in
them. Model
car s have a much mor e restricted air fl ow over the engine,so the oils that are used in the fu el fo r model cars help to cool
the engin
e. Using a model airplane fu el ma y cause the engine to run hollerthan desired.
FUEL BOTTLE
You will ne ed some sort of a fuel botlle in order to fill the tank in y our NXT with fue l. Your local hob b) sh op should have fuel bottles
available.
STARTERS
If y ou will be installing an engine that is not equipp ed with a pu ll -start, you will ne ed to have so me sort of an ele ct ric starter in order
to start the engine.
There are several hand-held electric starters ava il able on the mark eL Ther e are also a few manufa ct urers that
pr oduce starter boxes. A st arter box is easier to use, but is usually mor e expensive. When attemptingto start the engine in your NXT
truck with an el ec tric starter, make ce rtain that the engine is being turned the correct direction. Turning the engine over the wrong
dir
ec tion will cause the engine to run backwards.
GLOW IGNITER
You wi ll also need a glow plug igniter in order to st art the engine in yo ur NXT truck. There is a wide var iety of glow plug igniters
available.
Che ck with y our local ho bb y sbop.
TABLE OF CONTENTS
1. INTRODUCTION .......... .. ...................................... .... . .. ... i 2. BAG A ............................................................... .. ........ 1·4
Co mpleted Kit D im ensions .............................. .. .......... i 3. BAG B ........... .. ............................................................ 5·8
Notes & Symbols.......................................................... i 4. BAG C ....................................................................... 9-17
Kit Manual
Org amzation ......................................... .. .... i 5. BAG D .................................... .. ............................... 18·23
Important Safe ty Notes .. . .. .. ... .. .. .... .. .. .. ..... .. ... .. ... .. .. ... i 6.BAG E ............................................. .. ...................... 24·27
To ols Requtred ...................... .. ........... .. ........ .. ........ .. .... i 7.BAG F .................................................
.. ....................... 28
Radio/Eiectncal .. ............................. .. ...........................ii 8. Engine Installation................................................... 29·37
Hardware Identification . .... .......... .. .................. .. ...........ii 9. Radio Installation ........................................ .... ........ 38·46
Fuel................ .. ... .. .................. .. ........ .. ............. .. .......... ii 10. Final Assembly........................................................ 47 ·48
Fuel Bo ttle ................................................................... ii 11 . Final Checklist.............................................................. 48
Starters ........................
.. ....................... .. ............. .. ....... if 12.Tips from the Team ............................................... .. 49·51
Glow Ig niter . .. ... .. ....... .. ................... .. ............. .. .... .... ii 13. Spare parts .............. .. ............................................. 52- 55
Tto mL osi IS co nt i nu ally c han g in g a ruJ impr ov i ng dai gns ; thrr ifo rt, til t atluolf!ort ma y opp((J rs li g lltl y differen t than lit e il/u.stralcd part. 11/u malioiiS of part.r and assembli es may be
s lightly drsw rt ttlto rnhan « ptrtmro t dttails.
ii
sc an co urt esy ofVint ag elos i. com

BAGA
O mnnmlllllllllllli l
0 Step 1. Insert a 4--40 x 3/4" cap-head screw (I) through the
top middle hole on each side
of the front shock tower (2).Thread
a top shock mount bushing
(3) onto each ofthe two screws (I).
0 Step~ - lnsert aU~" ball stud (4) into the inside hole of the
two camber holes on the bottom of the shock tower (2). Mount
the ball studs (4) from the sameside ofthe shock tower (2) as the
screws (I) on both sides
of the shock tower (2). Secure the ball
studs (4) with 4-40 locknuts (5).
U!.l'!i¥1
0 Step 3. Secure the front shock tower (2) to the front bulk-
he ad (6) with two ~ ~- 40 x 71 8" cap-head screws (7)asshown. The
screws (7) should exte nd through the front of the bulkhead (6).
Be sure that the shock
mou nt bushings (3) face thecorrect direc-
ti on as shown in Figure 2.
1
Figure 7
Figure 2

BAG A (Continued)
'1' ·
11
11¥
1
ULrn ______ ____,fl) ,
@
0 Step4.Attachlhe front suspensi on arms [l eft (8), right {9)] to
the front bulkhead (6)
by sliding a 1/ 8'' inner front hinge pin (10 )
through the arm (8), (9) and bulkhead (6 ). Center the hinge pin
(
10 ) and secure il with two J/8" E·dips (IJ).
,& IMPORTANT NOTE: Be sure that the arms sweep to the
rear
and the shock mounting area is fa cing up.
0' · '111¥
1
0 Step 5. Attach the front body mount slide (12 ) to lhe front
side
of the front body mount support ( 13 ) by threading two 4-40
x 318" cap·head screws ( 14 ) into the lop hole io the body mow1t
slide { 12 ) ( this hole does not go all the way throu gh ) and Lhrough
Lhe holes in the body mount support (13) as shown.
0 Step 6. Placethe body mowllsupport(13)overthe lwo sc n ~ws
(7}extendingfrom the front of the bulkhead (6) so that the body
mount support ( 13 ) angles forward. Secure the body mount as-
semblywith lwo 4-40 locknuts (5).
WOTE: Assure that the body mount slide (72) angles down and to-
wards tile fron L
Figure 3
Figure 4
2

BAG A (Continued)
Ut.l'iiii
(??) ...... ro - - - -"'n m
@ @ @
D Step 7. Slide a front axle { 15 ) into the right spindle { 16 ) so
that
the hole in theaxle {1 5) lines up with the hole in thespindle
( 16 ).
'WOTE: Spindks are marked willl 'L ' and 'R' to designate left and
rig Itt.
D Step 8. Place th e assembl ed spindle (1 6) and axle ( 15 ) in the
rightspindle carrier (1 7) so tbat the letteron the spindle ( 16 ) faces
up. Insert a
118" x .960" hinge pin ( 18 ) through the spindle car-
rier (17), spindle { 16 ), and axle ( 15 ). Center the hinge pin ( 18 ) in
the assembly and secure it with two 1/8" E-clips (
II ).
D Step9. Ensure that the hingepin{ 18 )iscentered in thespindle
carrier (
17) and thread a 5·40 setscrew (19 ) into the rear of the
front axle (1 5). Tighten the setscrew against th e hinge pin ( 18 )
until
snug .
D Step 1 0. Place a studded baU washer (20} over a 3/8" ball
stud (4) and thread the ball stud into the top hole
of the spindle
carrier (
17 ), as shown, until snug. Thread a 3/16" ball stud { 21 )
into
the spindle from the top until snug.
&. I MPORTANT NOTE: Refer to the illustration and be cer -
tain that the spindle carrier and spindle are assembled correctly
and
th e reference tellers face the correct direction.
D Step I I. RepeatSteps 7-10 for the leftside parts (left spindle
{2 2), left spindle carrier ( 23 ) ).
UH'ii¥1
Db
@
D Step 12. Attach the right spindle carrierassembly to the right
suspension arm
(9) bysliding a 1/8" x.960" binge pin ( 18 )through
the
arm (9) andspindle carrier ( 17 ). Genter the hinge pin ( 18 ) in
the arm (
9} and secure it with two l/8" £-clips ( II ).
&. IMPORTANT NOTE: Make sure that the letter on the
spindle faces up.
D Step 13. Repeat Step 12 for left side.
3
@
Figur e5
Figure 6

BAG A (Continued)
'i[.!'!ifl
ljg
0 Step 1-l. Thread a plastic rod end (24) onto each end of a
1-7/8" turnbuckle { 2.5 ). Tighten both rod ends equally until the
rod is thesamelength as the rod shown in Figure 7
A. Mak e two of
the camber rod assemblies.
"NOTE: One md of the tumbuckle has left htmd threads. 171e included
Team Losi wrend1 can he used 011 /It t lt ex area of the turnbuckle .
0 tep IS. Place a "foam thing" (26) over each of the ball studs
{4) on the spindle carriers ( 17 }, (23) and the shock lower (2) . At-
tach one side of each camber rod assembly from Step 14 to the
ball stud (4) on the shock tower (2) and the other end to the ball
stud (4) on the spindle carrier (
17 ), (23}. Attach a camber rod to
both the left and the right side.
~ Mount all of the camber rods so that the adjustment hex is
to theoutside of the truck. Thi s will make future adjustments much
easier.
'it.!'ii¥
1
0 Step 16. Place the completed front suspension assembly on
the front
of the main chassis (27). Thread two 8-32 x 3/8 " screws
(28) through the two rear holes in the front portion
of the chassis
(27) and into the rear holes
in the front bulkhead (6).
0 Step 17. Align the fro nt bumper. (29) with the two fonvard
holes in the bottom of the chassis (27). Secure the bumper (29) to
the chassis by threading ~'-"o 8·32 x 3/8" screws (28) through the
bumper (
29 ), the chassis (27), and into the for.vard holes of the
front bulkhead {G). Tighten all four screws {28) until snug.
4
r
~ ~
~-- ~ --~
Figure 7
Figure 7A
Figure 8
.,
0
@...
Figure9 ~

BAG B
0 Step 1. Secure the steeringposts { 30 ) to theouter holesin the
front
of the chassis ( '.!7) using two 4-40 x 3/8" Oat ·head screws
(3 1) as shown.
>-<> Amild thread-lock compoundshould beused on all screws
thatare to be threaded into aluminum on this vehicle. Ifa thread-
lock compound isn't used, the vibration from the gas-powered
engine will cause the screws to back ouL
@
0 Step 2. Thread a 3/8" ba ll stud (4) into the outer hole on the
short arm of the steering bellcrank
(3 2) as shown. Tighten until
snug.
Do n ot overllghte n!
0 Step 3. Place a studded ball washer ( 20 ) over ea ch of two
3/ 1 6" ball studs ( 21 ) and thread one into each of the outer holes
in the steeringsector
arm (33} .
.&. I MP ORTANT NOTE: When [he ball studs face up, the
offset hole
in the sector arm should face forward on the left si de
as shown.
0 Step 4. Attach the steering beUcrank (32) to the sector arm
(33) by threading a 4· 40 x 1/ 8" cap-head shoulder-screw (3 4)
through the beUcrank (32) and into the offset hole an the sector
arm
(33) .
0 Step 5. Attach the steering idler arm {35) to lhc sector arm
(33) by threading a 4·40 x 1 /8" cap-head shoul der -screw (3 4)
through the
id ler ann (35) and into the remaining hole in the
sector
ar m (3 3). Tighten U1 e two cap·head shoulder-screws (: -14 ).
>-<> [f the bellcrank or idler arm doesn't rotate fr eely when
the sc rews are tightened, remove the screw and lightly file the
area around the threads on the sector arm. Attach the partagain
and check for free movement. fil e the arm slightly until the parts
rotate eas
ily. Again, it is a good idea to use a mild thread-lock
compound
in th e aluminum sector arm.
0 Step 6. Place the bellcrank (3 2) and idler am1 (35) ove;:r the
steering posts
(3 0) asshown. If you are asse mbli ng a Graphite
Plus kit, you must first install two 3/ 16 " x 51 16 " bearings (1 33)-
one in the top, one in the bottom -into the bellcrank (32) and
the idler arm ( 35 ) as shown in figure IIA.
5
~
I
Figure 70
Figure 77
Gra hite Plus Kit Only
Figrm 71A

BAG B (Continued)
U'·
11
!iif1
I ! t!IUIIIJ
0 Step 7. Thread a plastic rod end ( 24 ) onto each end of a
1 ·7/ 8" turnbuckle ( 25 ). Tighten both rod ends equally until the
rod is the same length as the r od shown in Figure 12A. Make two
of the tie-rod assemblies.
U'·
111
iif
1
0 Step 8. Attach one end of a tie-rod assembly to the ball stud
(21)
on the right side of the sector arm { 33 ) and the other end Lo
the ball stud {2 1) on the right spindle (16}.
0 Step 9. Repeat Step 8 for the left side.
,.._, Mount all of Lhe camber rods so that the adjustment hex is
to the outside of the truck. This will make future adjustments
much easier.
UH'!i¥1
1 ©
@
0 Step 10. Press a rubber tank-mounting grommet { 36 } into
each
of Lhe thcee lar ge holes in the top of the centerchassis brace
(37} as shown. The grommets {36) should be centered, lop·to·
bottom, in the holes of the chassis brace (3 7 ).
Q;==--,--~E=:=;:O
Figure 12A
Figure 73
Figure 14
6

BAG B (Continued)
'i' ·
11
iiif1
@
1-
@ @
0 Step 11. Line up the three posts on the fuel tank{ 38 ) with the
three holes with grommets in the cent er chassis bra ce (37). Install
the fuel tank (38) on the center chassis brace ( 37 ) from the bot - ®-
tom bypressingthe three posts on the t.an k { 38 ) through the three
rubbergrommets { 36 ).
0 Step 12. Place a -t4 washer( 39 ) over each of the tJuee 4-40 x
3/8'' cap-bead screws ( 14 ). Thread a screw (14 ) through each of
the grommets (36) and into the posts in thefuel tank (38). Ho ld
the tank (38) all the way up against the chassis brace(37).Tighten ~
each of thethreescre\vS ( 14 ) until the washer( 39 )justtouches the
grommet ( 36 ).
0'
"NOTE: 17ze scrws should not be tightmed so that the grommet smashes. Figure 75
By tightening tlte screws until the washers just touch the grommets, the
tt.mk will be ''shock mounted. '' Tltis helps to keep dw fuel from foami ng
while running tlu truck.
Ut.i
1iii1
1
0 Step 13. Refer lo figures 16A ru1d 16B. These are full-size
drawings of the steeringservo posts mountedin the two different
configurations. Hold y our serVO up to these diagrams and align
the mountingearson your servo with the holes in the posts. This
will determine how to mount the steeringservo posts ( 40 ).
0 Step 14. Once you have determi ned the mounting position
of the steering servo mounting posts (40), place the posts (40)
into the holes in the chassis (27) so that the posts are offset in the
correct direction from Figure 16A or 16B.
WOTE: If you do not !!ave your radio system yet, or do not kr10w which
servo you will use for steering at this time, mount tlte posts according to
Figure 76A and continue . The direction of the posts ca11 be dtanged once
you have determined which servo you will use.
& IMPORTANT NOTE: The 2nd and 5th hole from the
bottom in the servo mountingposts are largerthan the rest of the
holes. These holes should be positioned closest LO the chassis.
~
Figure 16
7
0
0
0
0
0
0
0
0
0
Figure 7 6A
Posts in ---· ..:. "'_.._
Figure 76B
c
0
0
0
0
0
0
0
;:)

BAG B (Continued )
@ t£D
0 Step l.S. Place the center chassis brace (37) on top of Lh e
chassis (27). Pay particular attention to the steering posts ( 30 )
and the servo mounting posts (40). The chassis brace has two
extensions lhal fit over the steeringposts ( 30 ), and the pins in
the top of the servo mounting posts (40) should fit imo two
holes in the chassis brace ( 37 ). Once the chassis brace is lin ed
up and in place, secure it to thefrontbulkhead (6} by threading
two 8- 32 x 31 8" screws {28) th rough the forward holes of the
chassis brace (37}and into theholes in thetop ofthe front bulk-
head (6 ).
D Step 1 6. Secure the chassis brace (37} to tl1e chassis {27}
with five 4-40 x 3/ 8" flat-head screws ( 31 ) as shown.
"NOTE: Mak sure that tl~e pins on the top and bottom of th e steering
seroo mount SUly located in the holes in the chassis and t!te dwssis
brace.
~ There is an extra 4-40 x 3/8" cap·head screw pac ked in
the wrench bag. Thisscrew can be used to tap the threads into
all of the "Stiffezell" plasticpartssuchas the centerchassis brace.
The larger cap·head uses a 3/3 2'' wrench which wi ll make it
easier to start threads into the stiff plastic than tlle small 1/ 16"
wrench used on the Oat-head screws. Applya thin coat of white
thrust beru·ing/assemblygrease ( 189 ) to tlle cap-beadscrew and
thread the screw in each of the holes about half way before
removingit.This will makeiteasier to install the flat·head screws
and allow for the last few threads to be tapped when it is in-
stalled.
Ol·''iii' :' ~
@
@ t
Figur e 77
0 Step J7. Refer to Figures 18A and 18B .These are full -size drawings of the throttle servo mounts (41) attached to the chassis in the
two different con fi gurations. Hold your servo up to these diagrams and align the mountingears on your servo to ho les in tl1e mounts.
This \vill detennine how to install the tllrottle servo mounts ( 41 ).
0 Step 18 . Once you have detennined themountingposition of the throttle servo mounts ( 41), attach each mount ( 41 ) to the chassis
(27}with two 4-40 x 3/ 8" D.at ·h ead screws { 31 )so that tlle rnow1ts are offset the correct way f1·om Figure 1 8A or I8B.
• NOTE: If you do not lwv e your radio system yet , or do not A·11ow wh.ich se roo you will use for throttle at this time, attad1 the servo mounts according
to Figure 18A and continue. The direction of the mounts can bec hat1ged ()nee y ou have determined whidt servo you will use.
~ Top hole• naccow
~ Figure 18A
Figure 78
F ~
Top holes wide 0
Figure 78B
8

BAGC
Bag C requires that you pay close attention to the bearings involved in the assembly (disregard this
note f
or kit#A -0810). Some bearings used during the assembly of this bag are very si milar in size. It
is important that you open the ba gs only as the y are n ee d ed. The bearings that are of conce rn are
packed in separate bags.
@
@
0 Step I. Insert a 4-40 mini locknut ( 42 } into the hex area of
the cliff nut canier ( 43 }. The thread-locking portion of the nut
( 42 )should face the outside.
0' ·
11
iii1·
1 @
@
0 Step 2. Locate the 5/64"Allen wrench ( 44 ·)suppliedwith the
kit. Place the diff nut carrier (43}, nut side llrst, over the Allen
wrench.
0 Step 3. Stack the six beveled washers (4 5} over the wrench,
nextto the
dilf nut carrier(43). The washers( 45 ) should all point
the same direction and open awa y from the nut carrier (43) as
shown.
0 Step 4. Place the cliff tube(46) over the wrench, big sidellrst,
so that it rests against the beveled washers (45).
0 Step 5. lnsertall of the parts that are stacked on the wrench
into one of the outdrive/diffhalves ( 47 ). Line up the tabs on the
di1T nut carrier (43}with the slots in the outdrive ( 47 }. Make cer·
lain that the dilftube { 46 }ispressedall the way into the outdrive/
diff half ( 47 }, and that it is straight. There is a small shoulder on
the diff tube( 46 } that should be Oush with the outer surface of the
outdrive (47 ).
0' ·
11
iiif1
0 tep 6. Apply a small amount of clear diffgrease ( 48 } to the
outside ring
of the outdrive (.J-7 ). Attach a diffwasher (49}to the
outdrive (
47 ) by lining up the slot in the washer(49}with the slot
in the outdrivc ( 47 ).
WOTE: Only a small amount of grease is needed. ll is only there to hold
the diff washer ir1 place.
6 IMPORTANT NOTE: Do not glue the cliff washers lo Lhe
outdrive/clill'halvcs. Do ing so may no l a ll ow the washersto mounl
flat.
9
Figure 79
=ff1 \\\\\\ A
~ /11/!l ld
Bevelled woshers shoUd face t his direc fl on
Figure 20
Figure 27
Figure 22

BAG C (Continued)
Uh
1
ii¥1
1
© 0
® ® @
0 Step 7. Inserta 5mm x 8mm bearing (50 )(5mm x 8mm bush-
ing { 51 ) if assembling kit #A - 0810) into the center of the diffgear
( 52 ).
0 Step8. Pressa 3/32" diffball (53) into each of thesmall holes
in the djff gear ( 52 ).
Ut.!'
1
ii&
1
0 Step 9. Apply a fairly heavy coal of clear diffgrease (48) to
the exposed side of the cliff washer (49) that is already attached
to the outdrive (47).
0 Step 10. Carefully place the cliff gear ( 52 ) over the cliff tube
(46) so that the diff balls ( 53 ) and cliff gear ( 52 ) rest against the
greased dill washer (49).
&IMPOR TANT NOTE: It is a good idea to hold the dill nut
carrierin placeso that the diff tube is not moved when the gear is
pushed over it
Ut.i
11
iifi © 0
0 Step 11. lnsert a 5mm x 8mm bearing (50) [5mm x 8mm
bushing( 51 ) if assembling kit* A-0810] into the secondoutdrive/
cliff half(47). Make sure that the bearing (50) [or bushing (5 1 )) is
pushedall the way irlto the outdrive (47). The handle of a hobb y
knife {with the bl ade removed) or a pencil can be used to push
the bearing ( .50 ) [or bushing{ 51)] into place.
0 Step 1 2. Drop the 1/ 4" x .5 / 16" shim ( 54 ) into the outdrive
( 47 ), on top of the 5 mm x 8mm beru'ing ( 50 ) [or bushing (.51)].
Make su re that theshim ( 54 }sits flat against the bearing( 50) [or
bushing { 51)1.
"NOTE: Be extra careful not to bend this shim!
10
Figure 23
Figure 24
Figure 25

BAG C (Continued)
0' · 11"111
@@
® ®
0 Step 13. Locate the diff adjusting screw (55) and place the
foam thrust bearingseal ( 56 )over the shoulder of the screw ( 5.5 ).
0 Step 14. Place one of the 3mm x 8mm thrust bearing wash·
crs (57) over the diffscrew (55).
0 Step 15 .Apply a liberal coal of white thrust bearing/assem-
bly grease (1 89) to the thrust washer ( 57 ) and place the 3mm x
8mm tluustbearing (5 8}over thescrew (55) and nextto the washer
(57). Grease the exposedside of the thrustbearing(58) with white
thrust bearing/assemblygrease(189) and place the second thrust
washer (5 7) over the screw and again st the thrust bear i ng (58).
0 Step 16. Very carefully insert the diff screw (55 ), with the
_ thrust bearingassembly installed, into the omdrive ( 47 }. Be very
careful not to bend or pinch the shim (54) while inserting the diff
screw (55). Pull the threaded end of the cliff screw (55) unt il the
thrust bearing assembly rests against the shim ( 54 }, next to the
bearing(50) (or bushing ( 51 } ], inside the outdrive { 47 ).
0' ·
11
1iiU
0 Step 17. Locate the smallest of the Allen wrenches { 44) and
place it in the slot in the out drive ( 47 ) containing the diff screw
{ 55 ). Slide the wrench all the way against the screw (55). By han-
dling the outdrive ( 47 ) with the wrench inserted, the diff screw
( 5.5 ) will be held in place while finish.ing assembly of the diff.
0 Step 18. Apply a small amount of clear grease ( 48 ) to the
outerring of the outdrive{ 47). Install the second diffwasher (49),
again lining up the slots in the outdrive (47) and the washer(49).
0 Step 19 . Apply a fairly heavy coat of clear diffgrease (· ~8 ) to
the exposed side of the diffwasher (49).
11
Figure 26
Figure 27

BAG C (Continued)
h'·!l
11
il
1
0 Step20. Wlule holdmglhedtffhalf{47)wnh the Allen wrench
inserted, carefully assemble the two outdrive/diff halves ( 47 ).
D Step 21. Makesure that the slot in the djffscrew ( 55 ) is lined
up with the slot in the outdrive {47) and the Allen wrench is in-
serted in the cliff screw (55).
D Step 22. Hold the diiT so that the outdrive (47) with the cliff
nutcarrier{43) is pointing up. Slowly tum the top cliffhalfclock-
wise to thread the cliff screw ( 55 ) into the -1 -- 40 mini nut (42}in
the diffnut carrier{43}. Thread the two halves together until the
screwjust starts to snug up.
•NOTE: lftht screw will not thrtad into tlu IIUl , mak£ sure that the nut
carrier is pushed all the way into the outdrive.
,._-;, When tightening the diiT , tighten the sc rew a little and
then "work" the diiT a little. Then tighten the screw a little more
and "work" the difT again. Continue t hi s until the diff is tight.
Thls wil l ensure that all the parts in the diff assembly are prop -
er ly sealed.
0 Step 23. Tighten the diffuntil the gear{52)cannot be turned
while boU1 of the outdrivcs (47) are being held firmly. It's better
to adjust the diiT too tight than too loose. Final diff adjustment
should be made after completion of the truck.
0[.('!11&
1
IIIUJIIJIIIIII!IIIIItiiiiUinill
0 Step 24. Thread the 1-40 x I" setscrew (59) all the way into
the threaded side of the slipper shaft (60). Make sure tl1at the
setscrew ( 59 ) is TIGHT!
:>-<> A small amount of liquid thread-lock will help to bold the
setscrew securely in place.
'it.i'"l'·'
D Step 2.5. Press the 1/ 1 6" x .5/ 1( )" spiro! pin ( 61) into thesmall
hole in the slippershaft ( 60) so that it extends even ly from boili
sides of the shaft { 60 }.
D Step 26. Slide the top gear ( 62 ) over the s li pper shaft (60)
from the side opposite the setscrew ( 59 ). Line up the groove in
thegear ( 62 ) with the pin (6I) and slide the gear (62) over the pin
( 61 ).
a Step 27. Secure the gear ( 62 ) to the shaft ( 60 ) by insertinga
3116" C-dip ( 63 ) into the groove in the slippershaft(60).
a Step 28. Slide the slipper shaft spacer ( 163 ) over the end of
the slipper shaft { 60 ) with the setscrew ( 59 ) so that the spacer
{ 163 ) rests against the gear ( 62 ).
- ---@
Figure 28
Figure 29
Figure 30
12

BAG C (Continued)
Ut.!'ii¥
11
©
0 Step29. Inserta 3/16" x 3/8" bearing(M) ( 3/ 16" x 3/8" bush·
ing (65) ifbuilding klt #A -08101 into the top bearing seat of the
left gearbox half(66).
0 Step30.Inserta 1/2"x 3/ 4- " bearing{ 67 ) [1 /2" x 3/4-" bushing
(68}ifbuilding kit
iA -0810) into the lower bearingseat of the left
gearbox half (66).
Ut.!'liifJ
og
(f?)
@ ©
@ @ @ @ @
0 Step3LInserta 3/ 16" x 3/8" bearing(64) [3/16" x 3/8" bush·
ing (65) if buildingkit iFA-0810) into the top bearing seat of the
right
gearbox half(69). Carefully push the bearing {6 4) [bushing
(6 5)] all the wayinto the bearingseat usinga pen or the handle of
a bobby knife {with the blade removed ). Care should be taken
not to damage the bearing shields.
0 Step 32 . Press, and lightly t ap the idler gear shaft (70), into
the hole in the center of the right gearbox half (6 9 ).
0 Step33.1nserta 1 /2" x 3/4" bearing{67} [112" x 3/ 4" bushing
(
68 ) if building kit iFA-0810] into the low er bearing seat of the
right gearbox
half {69).
0 Step 34. Attach a 1/8" E -c lip ( 11 ) to one end of the brak e
arm pin (
71 ) and pre ss the other end through the hole in the right
gearbox half(
69 ) as shown. Push the pin { 71 ) all the way in so
that the E-clip ( 11 ) is pushed against the inside of the right gear ·
box half(69).
13
Figur e 31
m ~
@ @
71
/
Fi g ur e32

BAG C (Continued)
0[.!'!iif
1 @
® @
0 Step35.Slidetheslippershaft (GO), thr ea ded s id e fir st, tlu-ough
the bearing ( 64 ·) (bushing ( 65)1 in the right geru· bo x half( 69 ).
0 Step 36. lnsert a 1/ 8" x 3/8" bearing ( 72 } [1 /8" x 3/ 8" bush-
ing ( 73 ) ifbuilding kit #A-{)810) into each side of the idler gear
( 7-l ). Pl ace the idler gear ( 74 } over the idler gear shaft { 70 ).
0 Step 3 7. in sert the differential assembly into the l/ 2" x 3/4"
bearing (67) (or bushing ( 68 )) in the right gearbox half( 69 ). In -
sert the differential diff nut carrier (4 3) side first.
"NOTE: Align the teeth on all gears when iTIStalling the differential.
>-<> If buildingkit *A - 08 10 with bushings, app ly a coat of white
thrust b earing /assembly grease to the in sides of the idler gear
bu shings before placing the gear on the shafL
U!.i'!i¥§
1 :lmn
mmi!11Iillllllll
l) nnnnnmmuttmttunlltlnD
@
0 Step 38. Carefu ll y assemble the left gea rbox half(66) to th e
comp l eted right gearbox half( 69 ).
0 Step 39. Thread the 4-40 x 3/4" cap -head scr ew (I) into the
rear hole in the transmission housing from
the left side. Do not
tighten the screw yet. just mug it up.
0 Step -1.0 . Sl i de the transmission brace {75) over the top shaft
and against
the right gearbox half( 69 ) so that the three holes in
the brace ( 75 } line up with the three holes in the gearbox half
(69). Slide a 4
-< W x 1-1/8" bu tton-head screw ( 76 ) thr ough the
top, forward hole
in the left gearbox ha lf ( (iCi ) and thread it into
the transmission brace (
75 ).
0 Step 41. Slide a 4- 40 x l-1/8" cap -h ea d scr ew ( 77 ) through
each
of the remaining two holes. Tighten all four transmission
screws.
>-<> There are outdriveshims ( 136 }included with your kiL These
shims can
be used. if necessary, to reduce the amount of end
play in the differential assembl y. After the transmission is as-
sembled and the SC'T('WS are tightPnPd, rhPrk thP amo unt of P.nci
pla y that the differential has. Id eally, there should be about a
business card's thickness worth
of end play. If there is m ore end
play than that, disassemble the trans mi ss ion a nd add shims until
the e
nd play is co rrect. The differential n ee ds to have a little e nd
pla y. If the differential has no end pla y, Lh e tran sm ission will
bind
once it heats up during extended run times.
14
Figure 33
!tllllt!!llJtnt
Figure 34

BAG C (Continued)
'*'''"**'
0 Step42. Glue one of the brake pads ( 78 }to the bottom of the
brake arm ( i9 ) just under the raised tab. A good cyanoacrylate
glue {superglue) should be used to hold the pad (78) in place.
The pad { 78 }should be position ed on the arm { 79 ) so that the
edge of the pad ( 78) is flush with the tab on the arm ( 7!)) and the
pad ( 78 ) should be ce nt ered so that it ex tends over each si de of
the brake arm (79) equall y. Press the pad ( 78 ) firmly in place with
your thumb while the glue sets. Th e pad ( 78 ) should be pressed
into placeso thatit matches the shape of the brake arm { 79 ). Cut
the secon d brake pad {78) so that you are left with a piece
1 /4 -1 /3 the original length. G lu e this smaller pad to the bra ke
arm (79} near the t op as shown in Figure 35. Again, ho ld the pad
in place so that it matches the shape of the brake arm { 79 }. The
gluejoint should be allowed about 112 hour to full y dry before
continuing. ='low 's a good time to read aheada Little inthe manual
to familiarize yourself with upcomingassemblies.
>-> Th e slipp er back plate/ brake drum can be used to hold
the brake pads to the brake ar m while the glue sets. Thi s will
ens ur e thatthe brake pads mak e fu ll co ntactwith the brake drum
once asse mbl y is comp let e.
0 Step 43. After the gl ue joints have been allowed time to set,
use a sharp hobby knife to carefully trim the edges of the br ake
pads (78) so that they are flush with the edges of the brake ann
(7 9}.
'i!.!'ii¥'1
@
0 Step 44. Slide the brake arm /pad assembly over the brake
arm pin (7 1) so that the brake arm forms an arc around the slip·
per shaft (6 0 ). Secure the brake arm ( 79 ) with a 1/8'' £-clip (II).
& IMPORTANf NOTE: The brakearm should be positioned
between the differential outdrive and the top shaft.
0 Step <IS. Press a 3/ 16" x 5/ 16" bushing{ 80 ) into the center of
the s pur gear (8 1 ).
15
Figure 35
I ~ ~
/ ~
G G
Figure 36
Figure 37

BAG C (Continued)
I jt .!l!lf!:l =Jit@l ;t.i
Kit #A-Q810 (Bushing Kit) Only
o@
0 Step 46. Slide the slipper back plate/brake drum { 82 }over the slippershaft{60),aligning the flat sections on the slippershaft {60)
with the flat sections of the back plate/brake drum { 82 ).
0 Step 47. Place the slipper pad ( 83 ) on the slipper gear plate ( 8~ ) and align the notches on the gear plate ( 84 ) with the notches on
the slipper pad (83).
0 Step48. Place the slipp er pad ( 83 ) and gear plate (84), pad side first, over the slipper shaft {60) a.od against the back plate/brake
drum ( 82 ). Try to get this assembly as close to center on the shaft (60) as possible.
0 Step 49. Carefullyinstall the spurgear{ 81 ) with the bushingside out. Lightly rotate the spur gear ( 81 ) until the three posts line up
with thethreeholes in the gear plate ( 84 ). Sna p the gear( 81) into placebeingcareful to keep theslipper pad (83) aligned with the gear
plate (84 .) .
0 Step 50. Place theslipper spring cup { 85 ), open side out, overthe shaft{60) and against the spurgear { 81 ).
0 Step 51. Insert one 1/·1" x9/ 16 " thrust washer(86) into the spring cup ( 85 ), then the 114 " x 9/16" thrust bearing(87), foUowed by
thesecond thrust washer {86). All three should be positioned all the way in the cup (85).
0 Step 52. Slide the slipper spacer (88), longside first, onto the shafl (6 0). The post on the spacer (88) should fit inside the thrust
bearing assembly.
0 Step 53. Place the gold slipper spring { 89 ) over the shaft{60),followed by the springretaining washer (90), and secure with the
4-40 locknut (5 ).
& IMPOR T ANT NOT E: Before tightening the nul, checkto see that the slipper pad is proper ly aHgne d with the gear plate. If it is
not, correct it before proceeding.
0 Step 54. Tighten the 4-40 locknut (5) all the way down, and t11en back it off one full turn {e.g., 360" x 1). This is a good starting
pointfor adjustment final adjustment can be made later.
Figure 38-Busl!ing
16

BAG C (Continued)
I a(. II I if I:§: i%1 ij I ,( .j
0 Step46. Slide theslipper back plate/brake drum ( 82 ) over theslip per shaft ( 60 ), aligning the nat sections on theslippershaft( 60 )
with the flat sections of the back plate/brake drum ( 82 ).
0 Step 47. Place one of the two slipper pads ( 83 ) on the slipp er gear plate ( 84 ) and align the notches on thegear plate ( 84 ) with th e
notches
on the slipper pad (83).
0 Step 48. Slide the slipper pad (83) and gear plate ( 84), pad side first, over the slippershaft ( 60 ) and against the back plate/brake
drum { 82). Try to get this assembly as close to center on theshaft (60}as possible.
0 Step 49. Carefully install the spur gear ( 81 ) with the three small posts facing the gear plate {84). Lightly rotate the spur gear ( 81 )
until the three posts line up with the three holes in the gear plate ( 84 }. Snap the gear (81) into place beingcareful to keep theslipper
pad ( 83 }aligned with the gear plate (84).
0 Step 50. Place the second slipper pad (83) against the outside of thespurgear( 81 ) and align the notches on the spur gear ( 81 )with
the notches on the slipper pad ( 83 ).
0 Step 51. Slide the outer s lipp er back plat e (107) over the s li pper s haf t (60) so that the sma ll shoulder on the back pl ate { 107 ) faces
the outsid e.
0 Step 52 . Slide the slipp er spacer ( 88 ) onto the shaft ( 60).
0 Step 53. Place the gold sli pper spring ( 89 ) over the shaft (60), followed by the spring retaining washer ( 90 ), and secure with Lh e
4 -40 locknut(5).
& IMPORTANT NOTE: Before tightening the nut, checkto see that the slipper pads are properlyaligned with the gear plate and
the sp ur gear. If they are not , correct the alignment before pro ceeding.
0 Step54. Tighten the 4- 40 lock nut (5) a ll the way down, and Lh en back it off three fulJ turns {e .g., 3600 x 3). This is a good starting
point for
ad ju stmen t. Final adjustment can be made later.
Figure J8-Beari11g
17