TLT Diff Shaft Mod

This mod has two benefits.  It will allow you to replace a broken diff shaft by removing only two screws from the steering knuckle.  Then all you have to do is slide the broken diff shaft out and sliding a replacement shaft in.  In this process we will also be meshing the beveled gear (pinion) so it will have adequate contact with the ring gear.  This reduces slippage which causes stripping of the ring and pinion

In a standard TLT setup, the differential shafts have an outer and inner C-clip.  The purpose of the C-clips is to prevent the diff shafts from shifting and holds the shafts in the axle.  In order for the mod to work we will not be using the inner C-clip.  However, eliminating the inner clips creates slop in the ring gear and greatly increases the chance of stripping out the ring and pinion.  This mod eliminates the slop by using shims (or washers in this case) to fill in the voids from removing the inner C-clips

Parts Needed;

Traxxas Fiber Washers 5x8mm Part no. 1985

HPI Washer M5x10x0.5mm Part no. HPIZ694

Blue spare rubber O-rings from Traxxas Shocks

Slide the M5x10x0.5mm washer, then the sealed bearing into the bevel gear shaft

Once complete, slide the pinion into the axle housing, insert the other outer bearing, then lock it in using the C-clip.  Here is an example of the a pinion without the shim installed and with one installed

Ring Gear

CA glue the nylon Traxxas 5x8mm washers to each end of the ring gear.  Be careful to center the shims to the outer holes and make sure not to get any CA glue into the treads.  Let it set till completely dry

For this next step you will only be using the outer clips on the diff shafts

Once the nylon shims have dried, place the ring gear into the housing, insert the bearings, then slide the diff shafts thru the bearings and into the ring gear.  You can see where the nylon washers (shims) have taken up the space where the C-clips once were.  This shimming will keep the ring gear from shifting in the housing

The last thing to do is insert the rubber O-rings into the back end of the axle stub.  This will reduce any slop and insures the diff shaft remains in place