Table of Contents:
1
1 Introduction
3
1.1
Pre-Installation Preparation
3
1.2
Tool-Kit Recommendations
4
1.3
Assembly Type Identification
5
2 Removing the Existing Differential
6
2.1
Vehicle Support
6
2.2
Differential Fluid Drain
6
2.3
Removing the Axles
7
2.4
Marking the Bearing Caps
8
2.5
Checking the Current Backlash Amount
9
2.6
Removing the Differential Carrier
10
3 Installing the Air Locker
12
3.1
Drilling and Tapping the Bulkhead Port
12
3.2
Approximate Backlash Shimming
13
3.3
Calculation & Selection of Backlash Shims
16
3.4
Assembling the Seal Housing
17
3.5
Installing the Carrier Bearings
18
3.6
Mounting the Ring Gear
18
3.7
Preload Shim Measurement
20
3.8
Setting up the Bulkhead Fitting
22
3.9
Profiling the Seal Housing Tube
24
3.10
Bench Testing the Air Locker
25
3.11
Reinstalling Differential and Axles
26
4 Installing the Air System
27
4.1
Mounting the Solenoid
27
4.2
Running & Securing the Air Line
29
4.3
Connection to the Bulkhead Fitting
30
5 Mounting & Connecting the Electrical System
32
5.1
Mounting the Actuator Switch(es)
32
5.2
Wiring the Actuator System
33
6 Testing & Final Assembly
36
6.1
Leak Testing
36
6.2
Testing the Air Locker Actuation
36
6.3
Filling the Differential
37
6.4
Post-Installation Check List
38
7 Parts List
39
7.1
Exploded Assembly Diagram
39
7.2
Specifications
39
7.3
Itemized Parts List
40
Summary of Contents for RD246
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