ARB RD166 - 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 Approximate Backlash Shimming 11
3.3 Mounting the Ring Gear 15
3.4 Drilling and Tapping the Bulkhead Port 16
3.5 Assembling the Seal Housing 17
3.6 Pre-­Load Shimming 18
3.7 Reinstalling the Bearing Caps 20
3.8 Checking the Backlash 21
3.9 Setting Up the Bulkhead Fitting 22
3.10 Profiling the Seal Housing Tube 24
3.111 Bench Testing the Air Locker 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 37
6.4 Re-­Sealing & Filling the Differential 37
6.5 Post-­Installation Check List 38
7 Parts List 39
7.1 Exploded Assembly Diagram 39
7.2 Itemized Parts List 40