ARB RD85 - 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 and Differential 5
2.4 Marking the Bearing Cap(s) 6
2.5 Checking the Current Backlash Amount 7
2.6 Spreading the Differential Housing 8
3 Bench Measurement 9
3.1 Measurement for Pre-Load Shimming 9
3.2 Calculation & Selection of Shims 11
4 Installing the Air Locker 12
4.1 Installing the Carrier Bearings 12
4.2 Mounting the Ring Gear 12
4.3 Drilling & Tapping the Bulkhead Port 14
4.4 Assembling the Differential Carrier 15
4.5 Approximating the Backlash for Tube Position 17
4.6 Marking the Bearing Cap for Tube Clearance 18
4.7 Modifying the Bearing Cap 19
4.8 Final Air Locker Assembly 21
4.9 Final Backlash Checking 22
4.10 Profiling the Seal Housing Tube 23
4.11 Setting up the Bulkhead Fitting 23
4.12 Bench Testing the Air Locker 25
4.13 Reinstalling the Differential and Axles 26
5 Installing the Air System 27
5.1 Mounting the Solenoid 27
5.2 Running & Securing the Air Line 29
5.3 Connection to the Bulkhead Fitting 30
6 Mounting & Connecting the Electrical System 31
6.1 Mounting the Actuator Switch(es) 31
6.2 Wiring the Actuator System 32
7 Testing & Final Assembly 36
7.1 Leak Testing 36
7.2 Testing the Air Locker Actuation 36
7.3 Re-Sealing & Filling the Differential 37
7.4 Post-Installation Check List 38
8 Parts List 39
8.1 Exploded Assembly Diagram 39
8.2 Itemized Parts List 40