ARB RD100 - 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 Disconnecting the Axles 7
2.4 Marking the Bearing Caps 8
2.5 Checking the Current Backlash Amount 9
2.6 Removing the Differential Center 10
3 Installing the Air Locker 12
3.1 Insuring Adequate Oil Drainage 12
3.2 Installing the Carrier Bearings 13
3.3 Approximate Backlash Shimming 14
3.4 Mounting the Ring Gear 16
3.5 Drilling and Tapping the Bulkhead Port 17
3.6 Assembling the Seal Housing 19
3.7 Pre-Load Shimming 20
3.8 Reinstalling the Bearing Caps 25
3.9 Checking the Backlash 26
3.10 Setting Up the Bulkhead Fitting 27
3.11 Profiling the Seal Housing Tube 29
4 Installing the Air System 30
4.1 Mounting the Solenoid 30
4.2 Running & Securing the Air Line 32
4.3 Connection to the Bulkhead Fitting 33
5 Mounting & Connecting the Electrical System 35
5.1 Mounting the Actuator Switch(es) 35
5.2 Wiring the Actuator System 36
6 Testing & Final Assembly 40
6.1 Leak Testing 40
6.2 Reinstalling the Axles 40
6.3 Testing the Air Locker Actuation 41
6.4 Re-Sealing & Filling the Differential 41
6.5 Post-Installation Check List 42
7 Parts List 43
7.1 Exploded Assembly Diagram 43
7.2 Itemized Parts List 44