ARB RD103 - 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 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 14
3.3 Approximate Backlash Shimming 15
3.4 Mounting the Ring Gear 17
3.5 Drilling and Tapping the Bulkhead Port 18
3.6 Assembling the Seal Housing 19
3.7 Pre-Load Shimming 20
3.8 Reinstalling the Bearing Caps 23
3.9 Checking the Backlash 24
3.10 Setting Up the Bulkhead Fitting 25
3.11 Profiling the Seal Housing Tube 27
4 Installing the Air System 28
4.1 Mounting the Solenoid 28
4.2 Running & Securing the Air Line 30
4.3 Connection to the Bulkhead Fitting 31
5 Mounting & Connecting the Electrical System 33
5.1 Mounting the Actuator Switch(es) 33
5.2 Wiring the Actuator System 34
6 Testing & Final Assembly 38
6.1 Leak Testing 38
6.2 Reinstalling the Axles 38
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