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
Disconnecting the Axles
6
2.4
Marking the Bearing Caps
6
2.5
Checking the Current Backlash Amount
7
2.6
Removing the Differential Center
8
3 Installing the Air Locker
10
3.1
Insuring Adequate Oil Drainage
10
3.2
Installing the Carrier Bearings
11
3.3
Approximate Backlash Shimming
12
3.4
Mounting the Ring Gear
15
3.5
Drilling and Tapping the Bulkhead Port
16
3.6
Assembling the Seal Housing
17
3.7
Pre-Load Shimming
18
3.8
Reinstalling the Bearing Caps
21
3.9
Checking the Backlash
22
3.10
Setting Up the Bulkhead Fitting
23
3.11
Profiling the Seal Housing Tube
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
Reinstalling the Axles
36
6.3
Testing the Air Locker Actuation
37
6.4
Re-Sealing & Filling the Differential
37
6.5
Post-Installation Check List
38
7 Parts List
39
7.1
Exploded Assembly Diagram
39
7.2
Itemized Parts List
40
