ARB RD90 - Manual (Page 24)

3 Installing the Air Locker
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c Make sure the seal housing tube and the grooves of the seal
housing are clean and free from any contaminants (e.g., water, dirt,
metal filings, etc.).
c Inspect the seal housing O-rings (supplied) for dirt, damage or
other conditions which might cause leaks.
c Generously lubricate the O-rings with oil prior to assembly, then
insert them into the grooves of the seal housing.
NOTE : When assembling the O-rings, be careful not to leave
them twisted when seated in the grooves as this could
cause excessive wear and leakage.
3.9.1 A Front Access Housing Installation
c Without using sharp, jagged tools such as pliers (usually your
hands are the best tool for this job), gently straighten the large
curve of the seal housing tube leaving only the sharp bends at both
ends of the tube.
c Install the seal housing onto the Air Locker by carefully sliding it
over the bearing journal by hand with a gentle twisting motion. This
will allow the O-rings to engage gently.
c Rotate the seal housing a few turns to make sure it rotates freely
and smoothly.
c While holding the bearing cup onto the carrier bearing opposite to
the seal housing, insert and hold the Air Locker into the differential
housing with the seal housing solder joint rotated to the top of the
differential housing (i.e., in line with the bulkhead port).
c Bend the seal housing tube around the outside of the ring gear until
the end of the tube can be inserted through the hole in the
bulkhead fitting.
c Assemble the shim packs ‘D’ and ‘E’ into their correct positions
between the bearing cups and the bearing bore of the housing.
NOTE : If the shim pack is too difficult to install then the
shims may need to be tapped in. Be careful not to
damage the shim packs while installing them.
c Install the bearing caps oriented as they were marked before they
were removed, and tighten the bearing cap bolts. It is not
necessary to torque them down at this time.
c Check that some backlash can be felt between the ring and pinion
gears. No backlash would be an early indication of incorrect shim
thickness.