ARB RD138 - 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 of the 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 8
3 Installing the Air Locker 9
3.1 Mounting the Ring Gear 9
3.2 Installing the Carrier Bearings 10
3.3 Drilling and Tapping the Bulkhead Port 11
3.4 Final Air Locker Assembly 12
3.5 Checking the Backlash 14
3.6 Installing the Seal Housing 15
3.7 Setting up the Bulkhead Fitting 17
3.8 Profiling the Seal Housing Tube 20
3.9 Bench Testing the Air Locker 22
3.10 Reinstalling the Differential & Axles 23
4 Installing the Air System 24
4.1 Mounting the Solenoid 24
4.2 Running & Securing the Air Line 26
4.3 Connection to the Bulkhead Fitting 27
5 Mounting & Connecting the Electrical System 29
5.1 Mounting the Actuator Switch(es) 29
5.2 Wiring the Actuator System 30
6 Testing & Final Assembly 33
6.1 Leak Testing 33
6.2 Testing the Air Locker Actuation 33
6.3 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