ARB RD90 - Manual (Page 3)

Table of Contents:
1
1 Introduction 3
1.1 Pre-Installation Preparation 3
1.2 Tool-Kit Recommendations 4
1.3 Assembly Type Identification 5
2 Removing the Existing Differential 6
2.1 Vehicle Support 6
2.2 Differential Fluid Drain 6
2.3 Removing the Differential Assembly 6
2.4 Checking the Current Backlash Amount 8
2.5 Removing the Differential Center 10
3 Installing the Air Locker 11
3.1 Approximate Backlash Shimming 11
3.2 Calculation & Selection of Backlash Shims 13
3.3 Mounting the Ring Gear 14
3.4 Installing the Carrier Bearings 15
3.5 Preload Shim Measurement 16
3.6 Calculation & Selection of Preload Shims 18
3.7 Drilling & Tapping the Bulkhead Port 19
3.8 Installing the Bulkhead Fitting 21
3.9 Installing the Differential Center 21
3.10 Setting Up the Bulkhead Fitting 24
3.11 Final Assembly 25
3.12 Checking the Backlash 27
3.13 Bench Testing the Air Locker 30
3.14 Reinstalling the Differential Assembly 31
4 Installing the Air System 32
4.1 Mounting the Solenoid 32
4.2 Running & Securing the Air Line 34
4.3 Connection to the Bulkhead Fitting 35
5 Mounting & Connecting the Electrical System 36
5.1 Mounting the Actuator Switch(es) 36
5.2 Wiring the Actuator System 37
6 Testing & Final Assembly 40
6.1 Leak Testing 40
6.2 Testing the Air Locker Actuation 40
6.3 Re-Sealing & Filling the Differential 41
6.4 Note For ADD Equipped Vehicles 41
6.5 Post-Installation Check List 42
7 Parts List 43
7.1 Exploded Assembly Diagram 43
7.2 Itemized Parts List 44