ARB RD110 - 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 Differential Assembly 5
2.4 Marking the Bearing Caps 6
2.5 Checking the Current Backlash Amount 7
2.6 Removing the Differential Center 8
3 Installing the Air Locker 9
3.1 Approximate Backlash Shimming 9
3.2 Calculation & Selection of Backlash Shims 11
3.3 Mounting the Ring Gear 12
3.4 Installing the Carrier Bearings 13
3.5 Preload Shim Measurement 14
3.6 Drilling & Tapping the Bulkhead Port 16
3.7 Installing the Bulkhead Fitting 17
3.8 Installing the Seal Housing 17
3.9 Installing the Differential Center 18
3.10 Setting Up the Bulkhead Fitting 20
3.11 Final Assembly 21
3.12 Checking the Backlash 23
3.13 Bench Testing the Air Locker 24
3.14 Reinstalling the Differential Assembly 25
4 Installing the Air System 26
4.1 Mounting the Solenoid 26
4.2 Running & Securing the Air Line 28
4.3 Connection to the Bulkhead Fitting 29
5 Mounting & Connecting the Electrical System 31
5.1 Mounting the Actuator Switch(es) 31
5.2 Wiring the Actuator System 32
6 Testing & Final Assembly 35
6.1 Leak Testing 35
6.2 Testing the Air Locker Actuation 35
6.3 Re-Sealing & Filling the Differential 36
6.4 Note For ADD Equipped Vehicles 36
6.5 Post-Installation Check List 37
7 Parts List 39
7.1 Exploded Assembly Diagram 39
7.2 Itemized Parts List 40