ARB RD197 - 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 8
2.6 Removing the Differential Center 11
3 Installing the Air Locker 12
3.1 Re-Mounting the Ring Gear 12
3.2 Drilling and Tapping the Bulkhead Port 13
3.3 Profiling the Seal Housing Tube (A) 15
3.4 Assembling the Seal Housing 17
3.5 Installing the Carrier Bearings 19
3.6 Final Air Locker Assembly 20
3.7 Profiling the Seal Housing Tube (B) 22
3.8 Checking the Backlash 23
3.9 Setting Up the Bulkhead Fitting 23
3.10 Reinstalling Differential and Axles 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 Testing the Air Locker Actuation 37
6.3 Re-Sealing & Filling the Differential 37
6.4 Post-Installation Check List 38
7 Parts List 39
7.1 Exploded Assembly Diagram 39
7.2 Itemized Parts List 40