ARB RD106 - 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
2.7 Use of the Thrust Block 9
3 Bench Measurement 10
3.1 Measurement for Pre-Load Shimming 10
3.2 Calculation & Selection of Shims 12
4 Installing the Air Locker 13
4.1 Insuring Adequate Oil Drainage 13
4.2 Installing the Carrier Bearings 16
4.3 Mounting the Ring Gear 17
4.4 Drilling & Tapping the Bulkhead Port 18
4.5 Assembling the Differential Carrier 19
4.6 Approximating the Backlash for Tube Position 20
4.7 Modifying the Bearing Cap 22
4.8 Air Locker Final Assembly 26
4.9 Final Backlash Checking 26
4.10 Profiling the Seal Housing Tube 28
4.11 Setting Up the Inner Bulkhead Fitting 29
4.12 Reinstalling the Axles 30
5 Installing the Air System 31
5.1 Mounting the Solenoid 31
5.2 Running & Securing the Air Line 33
5.3 Connection to the Bulkhead Fitting 34
6 Mounting & Connecting the Electrical System 36
6.1 Mounting the Actuator Switch(es) 36
6.2 Wiring the Actuator System 37
7 Testing & Final Assembly 41
7.1 Leak Testing 41
7.2 Testing the Air Locker Actuation 41
7.3 Re-Sealing & Filling the Differential 42
7.4 Post-Installation Check List 43
8 Parts List 45
8.1 Exploded Assembly Diagram 45
8.2 Itemized Parts List 46