ARB RD20 - 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 5
2.4 Marking the Bearing Caps 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 13
4.3 Drilling & Tapping the Bulkhead Port 14
4.4 Assembling the Differential Carrier 15
4.5 Approximating the Backlash for Tube Position 16
4.6 Marking the Bearing Cap for Tube Clearance 18
4.7 Modifying the Bearing Cap 20
4.8 Final Air Locker Assembly 22
4.9 Final Backlash Checking 23
4.10 Profiling the Seal Housing Tube 24
4.11 Setting up the Bulkhead Fitting 25
4.12 Reinstalling the Axles 27
5 Installing the Air System 28
5.1 Mounting the Solenoid 28
5.2 Running & Securing the Air Line 30
5.3 Connection to the Bulkhead Fitting 31
6 Mounting & Connecting the Electrical System 33
6.1 Mounting the Actuator Switch(es) 33
6.2 Wiring the Actuator System 34
7 Testing & Final Assembly 38
7.1 Leak Testing 38
7.2 Testing the Air Locker Actuation 38
7.3 Re-Sealing & Filling the Differential 39
7.4 Post-Installation Check List 40
8 Parts List 41
8.1 Exploded Assembly Diagram 41
8.2 Itemized Parts List 42