ARB RD107 - 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 Installing the Thrust Block 13
4.3 Mounting the Ring Gear 15
4.4 Drilling & Tapping the Bulkhead Port 16
4.5 Assembling the Differential Carrier 17
4.6 Approximating the Backlash for Tube Position 18
4.7 Modifying the Bearing Cap 20
4.8 Air Locker Final Assembly 24
4.9 Final Backlash Checking 24
4.10 Profiling the Seal Housing Tube 26
4.11 Setting Up the Inner Bulkhead Fitting 27
4.12 Reinstalling the Axles 28
5 Installing the Air System 31
5.1 Mounting the Solenoid 31
5.2 Running & Securing the Air Line 33
5.3 Connection to the Bulkhead Fitting 34
6 Mounting & Connecting the Electrical System 36
6.1 Mounting the Actuator Switch(es) 36
6.2 Wiring the Actuator System 37
7 Testing & Final Assembly 41
7.1 Leak Testing 41
7.2 Testing the Air Locker Actuation 41
7.3 Re-Sealing & Filling the Differential 42
7.4 Post-Installation Check List 43
8 Parts List 45
8.1 Exploded Assembly Diagram 45
8.2 Itemized Parts List 46