ARB Air Locker RD111, Installation Manual

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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 Differential Assembly 5
2.4 Checking the Current Backlash Amount 6
2.5 Removing the Differential Center 7
3 Installing the Air Locker 8
3.1 Approximate Backlash Shimming 8
3.2 Calculation & Selection of Backlash Shims 10
3.3 Mounting the Ring Gear 11
3.4 Installing the Carrier Bearings 12
3.5 Preload Shim Measurement 13
3.6 Calculation & Selection of Preload Shims 15
3.7 Drilling & Tapping the Bulkhead Port 15
3.8 Installing the Seal Housing 17
3.9 Installing the Bulkhead Fitting 19
3.10 Setting Up the Bulkhead Fitting 19
3.11 Final Assembly 20
3.12 Checking the Backlash 21
3.13 Bench Testing the Air Locker 23
3.14 Reinstalling the Differential Assembly 24
4 Installing the Air System 25
4.1 Mounting the Solenoid 25
4.2 Running & Securing the Air Line 27
4.3 Connection to the Bulkhead Fitting 28
5 Mounting & Connecting the Electrical System 29
5.1 Mounting the Actuator Switch(es) 29
5.2 Wiring the Actuator System 30
6 Testing & Final Assembly 33
6.1 Leak Testing 33
6.2 Testing the Air Locker Actuation 33
6.3 Re-Sealing & Filling the Differential 34
6.4 Post-Installation Check List 35
7 Parts List 37
7.1 Exploded Assembly Diagram 37
7.2 Specifications 37
7.3 Itemized Parts List 38