ARB RD99 - Manual (Page 3)

Table of Contents:
1
1 Introduction 3
1.1 Pre-Installation Preparation 3
1.2 Tool-Kit Recommendations 4
1.3 Assembly Type Identification 5
2 Removing the Existing Differential 6
2.1 Vehicle Support 6
2.2 Differential Fluid Drain 6
2.3 Removing the Axles 7
2.4 Marking the Bearing Caps 7
2.5 Checking the Current Backlash Amount 8
2.6 Removing the Differential Carrier 9
3 Installing the Air Locker 10
3.1 Installing the Carrier Bearings 10
3.2 Re-Mounting the Ring Gear 11
3.3 Drilling and Tapping the Bulkhead Port 12
3.4 Checking for Assembly Clearance 13
3.5 Checking the Backlash 15
3.6 Assembling the Seal Housing 16
3.7 Profiling the Seal Housing Tube 18
3.8 Setting Up the Bulkhead Fitting 19
3.9 Bench Testing the Air Locker 21
3.10 Reinstalling the Differential and Axles 22
4 Installing the Air System 23
4.1 Mounting the Solenoid 23
4.2 Running & Securing the Air Line 25
4.3 Connection to the Bulkhead Fitting 26
5 Mounting & Connecting the Electrical System 28
5.1 Mounting the Actuator Switch(es) 28
5.2 Wiring the Actuator System 29
6 Testing & Final Assembly 33
6.1 Leak Testing 33
6.2 Testing the Air Locker Actuation 34
6.3 Re-Sealing & Filling the Differential 34
6.4 Post-Installation Check List 35
7 Parts List 37
7.1 Exploded Assembly Diagram 37
7.2 Itemized Parts List 38