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 Bench Measurement
9
3.1
Measurement of Pre-Load 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
13
4.3
Drilling and Tapping the Bulkhead Port
14
4.4
Assembling the Differential Carrier
15
4.5
Calculation & Selection of Pre-Load Shims
16
4.6
Reinstalling the Bearing Caps
17
4.7
Checking the Backlash
18
4.8
Profiling the Seal Housing Tube
19
4.9
Setting Up the Bulkhead Fitting
20
4.10
Leak Testing the Air Locker
21
4.11
Reinstalling the 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
32
7.1
Leak Testing
32
7.2
Testing the Air Locker Actuation
32
7.3
Re-Sealing & Filling the Differential
33
7.4
Post-Installation Check List
34
8 Parts List
35
8.1
Exploded Assembly Diagram
35
8.2
Itemized Parts List
36
