ARB RD94 - Manual (Page 3)

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 Removal of Axles and Differential 5
2.4 Marking the Bearing Caps 6
2.5 Checking the Current Backlash Amount 7
2.6 Removing the Differential Carrier 7
3 Bench Measurement 8
3.1 Measurement for Pre-Load Shimming 8
3.2 Calculation & Selection of Shims 10
4 Installing the Air Locker 11
4.1 Installing the Carrier Bearings 11
4.2 Mounting the Ring Gear 12
4.3 Drilling & Tapping the Bulkhead Port 13
4.4 Assembling the Differential Carrier 14
4.5 Modifying the Bearing Cap 16
4.6 Final Air Locker Assembly 17
4.7 Final Backlash Checking 18
4.8 Profiling the Seal Housing Tube 19
4.9 Setting up the Bulkhead Fitting 21
4.10 Bench Testing the Air Locker 23
4.11 Reinstalling the Axles 24
5 Installing the Air System 25
5.1 Mounting the Solenoid 25
5.2 Running & Securing the Air Line 27
5.3 Connection to the Bulkhead Fitting 28
6 Mounting & Connecting the Electrical System 29
6.1 Mounting the Actuator Switch(es) 29
6.2 Wiring the Actuator System 30
7 Testing & Final Assembly 34
7.1 Leak Testing 34
7.2 Testing the Air Locker Actuation 34
7.3 Filling the Differential 35
7.4 Post-Installation Check List 36
8 Parts List 37
8.1 Exploded Assembly Diagram 37
8.2 Itemized Parts List 38