PTS Installation Instructions

Pts Installation Instructions PTS_Installation_Instructions PTS_Installation_Instructions 1271 file instruction uploads sonnax-dev

Pts Installation Instructions PTS_Installation_Instructions PTS_Installation_Instructions 1274 file instruction uploads sonnax-dev

Pts Installation Instructions PTS_Installation_Instructions PTS_Installation_Instructions 1263 file instruction uploads sonnax-dev

Pts Installation Instructions PTS_Installation_Instructions PTS_Installation_Instructions 1277 file instruction uploads sonnax-dev

Pts Installation Instructions PTS_Installation_Instructions PTS_Installation_Instructions 1276 file instruction uploads sonnax-dev

2016-05-23

: Sonnax Pts Installation Instructions PTS_Installation_Instructions 1267 file instruction uploads

Open the PDF directly: View PDF PDF.
Page Count: 2

DownloadPTS Installation Instructions
Open PDF In BrowserView PDF
POWER TRAIN SAVERS

A D VANC ED DR IVEL INE PROTECTION SYSTE M
Instructions

Power Train Savers

®

Light, Medium & Heavy Duty

Light Duty

Medium Duty

Welding Procedure for PTS Installation
Preparation of Driveshaft
All loose or thick scale, rust, moisture, grease, paint or other
foreign material that would prevent proper welding or produce
objectionable fumes should be removed to within 2" of weld
location. The repair area should be prepared by machining or
grinding to remove any burrs or surface defects and to ensure
squareness of tube ends.
Preheat
Preheating of the PTS is not necessary and should not be done.
Weld at room temperature (68°F/20°C). The driveline tube can be
preheated if needed.
Welder Settings
All welders are different. Some may have to be adjusted higher
or lower to produce the same amperage. The following are
average settings:
• Voltage: 19-21	 • Amperage: 195-200
Weld Procedure
The welding process will be flux cored arc welding (FCAW) process, semi-automatic using an E4801 T-9 CH electrode with a
75/25% shielding gas. Use only stringer beads with a radial direction of travel. The driveline should be mounted on rollers and
rotated to maintain a flat or horizontal welding position with a
controlled rate of weld deposit.
• Slag or flux remaining after a pass must be removed before
applying the next pass. Similarly, cracks or blowholes which
appear on the surface of any pass must be removed before depositing the next pass.
• Care must be used to prevent the containment or trapping of
slag, the formation of voids or root porosity.
©2016 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

Heavy Duty

• Weld geometry must be free from undercut, cold laps and poor
transitions, and must be consistent with acceptable weld profiles.
Cooling of Driveline
The best method is to air-cool welds slowly at room temperature.
Do not rush the cooling process by quenching the welds with coolant or water, as this can cause stress cracks not noticeable to the eye.
Installation
	
	

IMPORTANT: A qualified driveline technician must install the
Power Train Saver.

The Power Train Saver (PTS) should normally be installed directly
in front of the forward differential, on the weld yoke end of the
shaft (Figure 1 driveshaft “A”).
In some cases, when the driveshaft angles and RPM exceed manufacturer specifications, the PTS can be installed ahead of the carrier bearing (Figure 1 driveshaft “B”).
In either case, the PTS must be installed on the weld yoke end
of the driveshaft.
1. Check PTS part number. Cut and discard the appropriate
portion of driveshaft based on the PTS being installed using the dimensions shown in Figure 1, then machine tube
ends square.
2. Align the timing marks on the outside diameter of the PTS
and install the Torque Fuses® according to the instructions
packed with the fuse set. The nuts must be tightened to the
torque specification given.
3. Install the PTS into the longer section of the driveshaft.
Make sure the PTS is square with the tube and tack weld
it in place.
PTS_Instructions 05-23-16
Page 1

POWER TRAIN SAVERS

A D VANC ED DR IVEL INE PROTECTION SYSTE M
Instructions

POWER TRAIN SAVERS ® LIGHT, MEDIUM & HEAVY DUTY

Figure 1
Start cut 3.000"
from weld line.

Start cut 3.000"
from weld line.
A

B

Discarded Portion
from A or B

Differential

Part Numbers

3.500"

20083B, 20120B, 25083B, 25095B, 25120B

4.505"

15095, 16134, 17180, 18134, 18259, SP138, 30083, 35083, 35095, 40083, 40180

6.000"

SP165, SP197

Installation (continued)
4. Radial run out of the PTS must be .002" or less
when measured (Figure 2). Once correct positioning
has been verified, complete the weld and re-measure.

Tack and weld
(long end).

Figure 2

5. Tack and weld the short end of the driveshaft to the
PTS as shown in Figure 3.
6. Check the finished assembly for radial runout at the
locations shown in Figure 3. No part of the assembly
should have more than .004" radial run out.

Check radial runout
on this surface.

7. Balance to within 0.2 ounce-inches on both ends of
the assembly.

Figure 3

Check Radial Runout

Weld Yoke

Differential

Tack and weld (short end).

Fuse Nut Torque Specifications
PTS Series
Light Duty

Fuse ID Stamp Code

Fuse Nut Hex

Fuse Nut Torque

1E — 1Q

3 /4"

80 Ft. Lbs.

Medium Duty

0 — 13

Heavy Duty

F—Z

©2016 Sonnax Industries, Inc.
800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com

15/

16"

140 Ft. Lbs.

11/8"

220 Ft. Lbs.

PTS_Instructions 05-23-16
Page 2
Source Exif Data: 
File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.7
Linearized                      : Yes
XMP Toolkit                     : Adobe XMP Core 5.3-c011 66.145661, 2012/02/06-14:56:27
Instance ID                     : uuid:1ba1205b-6cfc-4724-8ac3-c821b90c441c
Original Document ID            : adobe:docid:indd:e5616bf6-c535-11de-9b43-b8f1dfdc21f8
Document ID                     : xmp.id:59A8A4E4EC20E611BDFCEFC2BCF14BDA
Rendition Class                 : proof:pdf
Derived From Instance ID        : xmp.iid:58A8A4E4EC20E611BDFCEFC2BCF14BDA
Derived From Document ID        : xmp.did:21EF4358FDBDE011BD31E833B5BC579A
Derived From Original Document ID: adobe:docid:indd:e5616bf6-c535-11de-9b43-b8f1dfdc21f8
Derived From Rendition Class    : default
History Action                  : converted
History Parameters              : from application/x-indesign to application/pdf
History Software Agent          : Adobe InDesign CS6 (Windows)
History Changed                 : /
History When                    : 2016:05:23 09:49:50-04:00
Create Date                     : 2016:05:23 09:49:50-04:00
Modify Date                     : 2016:05:23 09:49:52-04:00
Metadata Date                   : 2016:05:23 09:49:52-04:00
Creator Tool                    : Adobe InDesign CS6 (Windows)
Format                          : application/pdf
Producer                        : Adobe PDF Library 10.0.1
Trapped                         : False
Page Count                      : 2
Creator                         : Adobe InDesign CS6 (Windows)
EXIF Metadata provided by EXIF.tools

Navigation menu