ARB RD116 - Manual (Page 3)

Table of Contents:
1
1 Introduction 3
1.1 Pre-Installation Preparation 3
1.2 Tool-Kit Recommendations 4
2 Removing the Existing Differential 5
2.1 Vehicle Support 5
2.2 Differential Fluid Drain 5
2.3 Disconnecting the Axles 6
2.4 Marking the Bearing Caps 6
2.5 Checking the Current Backlash Amount 7
2.6 Removing the Differential Center 8
3 Installing the Air Locker 10
3.1 Insuring Adequate Oil Drainage 10
3.2 Installing the Carrier Bearings 11
3.3 Approximate Backlash Shimming 12
3.4 Mounting the Ring Gear 15
3.5 Drilling and Tapping the Bulkhead Port 16
3.6 Assembling the Seal Housing 17
3.7 Pre-Load Shimming 18
3.8 Reinstalling the Bearing Caps 21
3.9 Checking the Backlash 22
3.10 Setting Up the Bulkhead Fitting 23
3.11 Profiling the Seal Housing Tube 25
4 Installing the Air System 26
4.1 Mounting the Solenoid 26
4.2 Running & Securing the Air Line 28
4.3 Connection to the Bulkhead Fitting 29
5 Mounting & Connecting the Electrical System 31
5.1 Mounting the Actuator Switch(es) 31
5.2 Wiring the Actuator System 32
6 Testing & Final Assembly 36
6.1 Leak Testing 36
6.2 Reinstalling the Axles 36
6.3 Testing the Air Locker Actuation 38
6.4 Re-Sealing & Filling the Differential 38
6.5 Post-Installation Check List 39
7 Parts List 41
7.1 Exploded Assembly Diagram 41
7.2 Itemized Parts List 42