ARB RD137 - 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 and Differential 5
2.4 Marking the Bearing Caps 6
2.5 Checking the Current Backlash Amount 6
2.6 Spreading the Differential Housing 8
3 Bench Measurement 9
3.1 Approximate Backlash 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 12
4.3 Assembling the Seal Housing 13
4.4 Calculation & Selection of Pre-Load Shims 14
4.5 Drilling and Tapping the Bulkhead Port 15
4.6 Modifying the Bearing Cap 16
4.7 Final Air Locker Assembly 17
4.8 Final Backlash Checking 17
4.9 Profiling the Seal Housing Tube 18
4.10 Setting up the Bulkhead Fitting 20
4.11 Bench Testing the Air Locker 21
4.12 Reinstalling the Differential and 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 31
7.1 Leak Testing 31
7.2 Testing the Air Locker Actuation 31
7.3 Filling the Differential 32
7.4 Post-Installation Check List 33
8 Parts List 35
8.1 Exploded Assembly Diagram 35
8.2 Itemized Parts List 36