ARB RD81 - 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 Removing the Axles 5
2.4 Marking the Bearing Caps 6
2.5 Checking the Current Backlash Amount 7
2.6 Spreading the Differential Housing 8
3 Approximate Backlash Shimming 10
3.1 Bench Measurement 10
3.2 Calculation and Selection of Pre-Load Shims 12
4 Installing the Air Locker 13
4.1 Mounting the Ring Gear 13
4.2 Installing the Carrier Bearings 14
4.3 Drilling and Tapping the Bulkhead Port 15
4.4 Pre-Load Shimming 16
4.5 Checking the Backlash 18
4.6 Profiling the Seal Housing Tube 19
4.7 Setting up the Bulkhead Fitting 21
4.8 Re-Installing the Axles 23
5 Installing the Air System 24
5.1 Mounting the Solenoid 24
5.2 Running & Securing the Air Line 26
5.3 Connection to the Bulkhead Fitting 27
6 Mounting & Connecting the Electrical System 29
6.1 Mounting the Actuator Switch(es) 29
6.2 Wiring the Actuator System 30
7 Testing & Final Assembly 33
7.1 Leak Testing 33
7.2 Testing the Air Locker Actuation 33
7.3 Re-Sealing & Filling the Differential 34
7.4 Post-Installation Check List 35
8 Parts List 37
8.1 Exploded Assembly Diagram 37
8.2 Itemized Parts List 38