Installation of the Air System
NOTE: Verify all threads when using non-Yukon parts for replacement.
• Remove one of the 1/8” BSP plugs from the compressor port. Apply Teflon tape or sealer to one of the 1/8” BSP nipples and thread into the port.
• Tighten the fitting down and apply Teflon tape or sealer to the threads which face outward as well.
• Attach the solenoid to the fitting and tighten down, making sure that the solenoid does not interfere with any other fittings on the compressor.
• Apply Teflon tape or sealer to the 1/8” BSP push-to-connect fitting and tighten it into the solenoid outlet port.
Notes on Air Supply
The following air supply requirements must be met in order for the unit to work properly:
• Unit must maintain at least 85 PSI.
• Unit must not exceed 110 PSI at any time.
• Clean air must be provided as to not clog the air lines.
• Solenoid must be mounted in relatively close proximity to the air supply
Depending on the modifications to your vehicle, the path in which you run your air line will vary from application to application. However, there are some general guidelines to take into account when running the air lines for your Zip Locker® differential.
• Try to keep the air line from dangling in such a way to where it may get caught on foreign objects such as rocks, branches, etc.
• Keep the air line away from anything on the vehicle which could potentially damage it. Be sure to keep it away from hot objects such as exhaust and sharp objects which may puncture or cut it.
• Try to keep the line from kinking around objects which may result in blocking the air from getting to the locker.
• Make sure to take suspension travel into account when running the air line to avoid the line getting pulled on .
• Run the line all the way from the compressor to the housing before attaching or trimming it.
Connecting air line to bulkhead fitting
• Start by connecting one end of the air line to the push-to-connect fitting on the solenoid.
• After running the air line in a good route and securing it, trim it to the proper length with a sharp knife.
• Insert the end of the airline into the push-to-connect fitting located on the differential.
NOTE: When cutting the plastic airline be sure to leave a flat square edge on the cut surface. A flat surface on the end of the air line will help ensure proper engagement into the push-to-connect fittings. Firmly press the air line into the fitting until bottoming out. Test connection by pulling outward on the air line ensuring no movement takes place.
Testing for Leaks
NOTE: Your vehicle should not be on during this testing period.
• Turn compressor on and allow the system to charge. Once charged, the compressor should not come back on while lockers are disengaged. If compressor does come back on, this would be an indication of a leak.
• Actuate the Zip Locker®(s) and wait to see if compressor recharges the tank. If the compressor comes back on within 10 minutes, you may have a leak in your system.
• If you believe you have a leak, spray all fittings with a solution of soap/water mixture and look for bubbles. If bubbles are present, try tightening the fitting and check to see if the leak persists. If bubbles are still present, disassemble the fitting in question and reapply Teflon tape or sealer.
To install the C-Clips into your axles, take the following steps:
• Remove cross pin from the Zip Locker® by removing the cross pin bolt and pulling out retaining pin with the supplied retaining pin removal tool.