ARB RD40 - Manual (Page 3)

Table of Contents:
1
1 Introduction 3
1.1 Pre-Installation Preparation 1.2
1.3 Tool-Kit Recommendations 1.4
2 Removing the Existing Differential 5
2.1 Vehicle Support 5
2.2 Differential Fluid Drain 5
2.3 Removing the Axles 5
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 Mounting the Ring Gear 10
3.3 Drilling & Tapping the Bulkhead Port 11
3.4 Assembling the Differential Carrier 12
3.5 Approximating the Backlash for Tube Position 12
3.6 Marking the Bearing Cap for Tube Clearance 13
3.7 Modifying the Bearing Cap 15
3.8 Final Air Locker Assembly 17
3.9 Checking the Backlash 17
3.10 Profiling the Seal Housing Tube 19
3.11 Setting up the Bulkhead Fitting 19
3.12 Reinstalling the Axles 21
4 Installing the Air System 22
4.1 Mounting the Solenoid 22
4.2 Running & Securing the Air Line 24
4.3 Connection to the Bulkhead Fitting 25
5 Mounting & Connecting the Electrical System 27
5.1 Mounting the Actuator Switch(es) 27
5.2 Wiring the Actuator System 28
6 Testing & Final Assembly 32
6.1 Leak Testing 32
6.2 Testing the Air Locker Actuation 32
6.3 Re-Sealing & Filling the Differential 33
6.4 Post-Installation Check List 34
7 Parts List 35
7.1 Exploded Assembly Diagram 35
7.2 Itemized Parts List 36