ARB RD119 - 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 Removing the Axles 6
2.4 Marking the Bearing Caps 6
2.5 Checking the Current Backlash Amount 7
2.6 Removing the Differential Carrier 8
3 Installing the Air Locker 9
3.1 Installing the Carrier Bearings 9
3.2 Re-Mounting the Ring Gear 10
3.3 Drilling and Tapping the Bulkhead Port 11
3.4 Checking for Assembly Clearance 12
3.5 Checking the Backlash 15
3.6 Assembling the Seal Housing 17
3.7 Profiling the Seal Housing Tube 19
3.8 Setting Up the Bulkhead Fitting 20
3.9 Bench Testing the Air Locker 22
3.10 Reinstalling the Differential and Axles 23
4 Installing the Air System 24
4.1 Mounting the Solenoid 24
4.2 Running & Securing the Air Line 26
4.3 Connection to the Bulkhead Fitting 27
5 Mounting & Connecting the Electrical System 29
5.1 Mounting the Actuator Switch(es) 29
5.2 Wiring the Actuator System 30
6 Testing & Final Assembly 34
6.1 Leak Testing 34
6.2 Testing the Air Locker Actuation 35
6.3 Re-Sealing & Filling the Differential 35
6.4 Post-Installation Check List 36
7 Parts List 37
7.1 Exploded Assembly Diagram 37
7.2 Itemized Parts List 38