ARB RD158 - 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 Disconnecting the Axles 6
2.4 Marking the Bearing Caps 6
2.5 Checking the Current Backlash Amount 7
2.6 Removing the Differential Center 8
3 Bench Measurement 9
3.1 Measurement of 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 Mounting the Ring Gear 13
4.3 Drilling and Tapping the Bulkhead Port 14
4.4 Assembling the Differential Carrier 15
4.5 Calculation & Selection of Pre-Load Shims 16
4.6 Reinstalling the Bearing Caps 17
4.7 Checking the Backlash 18
4.8 Profiling the Seal Housing Tube 19
4.9 Setting Up the Bulkhead Fitting 20
4.10 Leak Testing the Air Locker 21
4.11 Reinstalling the Axles 22
5 Installing the Air System 23
5.1 Mounting the Solenoid 23
5.2 Running & Securing the Air Line 25
5.3 Connection to the Bulkhead Fitting 26
6 Mounting & Connecting the Electrical System 27
6.1 Mounting the Actuator Switch(es) 27
6.2 Wiring the Actuator System 28
7 Testing & Final Assembly 32
7.1 Leak Testing 32
7.2 Testing the Air Locker Actuation 32
7.3 Re-Sealing & Filling the Differential 33
7.4 Post-Installation Check List 34
8 Parts List 35
8.1 Exploded Assembly Diagram 35
8.2 Itemized Parts List 36