ARB RD44 - 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 Axle 5
2.4 Marking the Bearing Caps 6
2.5 Checking the Current Backlash Amount 7
2.6 Spreading the Differential Housing 8
2.7 Use of the Thrust Block 9
3 Bench Measurement 10
3.1 Measurement for Pre-Load Shimming 10
3.2 Calculation & Selection of Shims 12
4 Installing the Air Locker 13
4.1 Installing the Carrier Bearings 13
4.2 Mounting the Ring Gear 14
4.3 Drilling & Tapping the Bulkhead Port 15
4.4 Assembling the Differential Carrier 16
4.5 Approximating the Backlash for Tube Position 17
4.6 Marking the Bearing Cap for Tube Clearance 19
4.7 Modifying the Bearing Cap 21
4.8 Final Air Locker Assembly 23
4.9 Final Backlash Checking 23
4.10 Profiling the Seal Housing Tube 25
4.11 Setting up the Bulkhead Fitting 25
4.12 Reinstalling the Axles 27
4.13 Bench Testing the Air Locker 28
5 Installing the Air System 29
5.1 Mounting the Solenoid 29
5.2 Running & Securing the Air Line 31
5.3 Connection to the Bulkhead Fitting 32
6 Mounting & Connecting the Electrical System 34
6.1 Mounting the Actuator Switch(es) 34
6.2 Wiring the Actuator System 35
7 Testing & Final Assembly 39
7.1 Leak Testing 39
7.2 Testing the Air Locker Actuation 39
7.3 Re-Sealing & Filling the Differential 40
7.4 Post-Installation Check List 41
8 Parts List 43
8.1 Exploded Assembly Diagram 43
8.2 Itemized Parts List 44