ARB RD168 - 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 7
2.5 Checking the Current Backlash Amount 8
2.6 Removing the Differential Center 9
3 Installing the Air Locker 11
3.1 Insuring Adequate Oil Drainage 11
3.2 Approximate Backlash Shimming 12
3.3 Mounting the Ring Gear 16
3.4 Drilling and Tapping the Bulkhead Port 17
3.5 Assembling the Seal Housing 18
3.6 Pre-Load Shimming 19
3.7 Reinstalling the Bearing Caps 20
3.8 Checking the Backlash 21
3.9 Setting Up the Bulkhead Fitting 22
3.10 Profiling the Seal Housing Tube 24
3.11 Bench Testing the Air Locker 25
4 Installing the Air System 26
4.1 Mounting the Solenoid 26
4.2 Running & Securing the Air Line 28
4.3 Connection to the Bulkhead Fitting 29
5 Mounting & Connecting the Electrical System 31
5.1 Mounting the Actuator Switch(es) 31
5.2 Wiring the Actuator System 32
6 Testing & Final Assembly 36
6.1 Leak Testing 36
6.2 Reinstalling the Axles 36
6.3 Testing the Air Locker Actuation 39
6.4 Re-Sealing & Filling the Differential 39
6.5 Post-Installation Check List 40
7 Parts List 41
7.1 Exploded Assembly Diagram 41
7.2 Itemized Parts List 42