ARB Air Locker RD111 Installation Manual Download Page 38

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6 Testing & Final Assembly

6.4

Post-Installation Check List

Now that the

Air Locker

installation has been completed, ARB

recommends that you take the time to complete the following check list
just to insure that you haven’t missed any of the vital steps.



The air system has been leak tested.



Thread locking compound was used on the ring gear bolts.



All torque settings comply with the ve

hicle manufacturer’s specs

and were set with an accurate torque wrench.



Differential fluid complies with ARB recommendations and has
been filled to the correct level.



All air lines and wiring have been securely cable tied to resist
snagging.



Switch(es) have been securely mounted within operator reach, yet
well away from danger of accidental engagement.



Switch(es) function correctly and illuminate to indicate that

Air

Locker

(s) have been engaged.



The

Air Locker

Warning Sticker has been located within close

proximity of the actuator switch(es).



All operators who are to use the

Air Locker

have read, and fully

understand the

ARB Air Locker Operating & Service Manual.

INSTALLATION PERFORMED BY:

DATE OF INSTALLATION:

ODOMETER READING:

AIR LOCKER SERIAL No.:

___________________________

Summary of Contents for Air Locker RD111

Page 1: ...RD111 TOYOTA 8 IFS 53MM CARRIER BEARING AIR OPERATED LOCKING DIFFERENTIAL INSTALLATION GUIDE ...

Page 2: ...er product names used herein are for identification purposes only and may be trademarks of their respective owners ARB 4x4 ACCESSORIES Corporate Head Office 42 44 Garden St Tel 61 3 9761 6622 Kilsyth Victoria Fax 61 3 9761 6807 AUSTRALIA 3137 Australian enquiries sales arb com au North South American enquiries sales arbusa com Other international enquiries exports arb com au www arb com au ...

Page 3: ...ng 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 Bulkhe...

Page 4: ...2 ...

Page 5: ...hough your ARB Air Locker comes complete with all the step by step instructions you will need to supplement your vehicle manufacturer s service manual and install your new differential ARB recommends that you have your Air Locker installed by a trained professional Many ARB distributors around the world have been fully instructed in Air Locker installations by ARB and have gained a wealth of exper...

Page 6: ...al for required torque range A lubricant drain reservoir A slide hammer for removing CV axles Suitable measuring tools to measure a differential for preload shimming e g an automotive feeler gauge A 11 2mm 7 16 drill and NPT tap for bulkhead fitting installation An automotive bearing puller 2 jawed or a differential carrier bearing puller A bearing press or arbor press 1 2 2 Supplies Thread lubric...

Page 7: ... differential component Once drained reinstall the drain plug 2 3 Removing the Differential Assembly Remove the stub axles from the differential housing according to your vehicle manufacturer s service manual NOTE Rubber oil seals can be easily damaged Support the weight of the axle when extracting it across the edges of the seals NOTE Some Toyota IFS axles can be removed easier by disconnecting t...

Page 8: ...to your vehicle service manual or your local authorized ARB installer for more information Set a long series lever type dial indicator on one of the ring gear teeth Access to the ring gear teeth is gained through the oil filler hole Refer to Figure 1 Figure 1 Insert a large flat screwdriver or pry bar through one of the axle stub holes so that it wedges between the cross shaft and the carrier body...

Page 9: ...Refer to your vehicle manufacturer s service manual Remove all bolts from around the outside of the clamshell Gently pry the clamshell apart and remove the differential center Using an arbor press remove both bearing cups and preload shims by pressing on the face of the shims through the housing from the outside NOTE Be sure not to mix up the left and right hand tapered roller bearing cups or prel...

Page 10: ...tabs used on some models will not be required on the Air Locker and may be discarded Using a plastic or copper hammer gently tap in a circle around the outside of the ring gear to separate it from the differential carrier Remove the original bearings from the differential center using a bearing puller NOTE Keep the bearings separated so that they can be identified as to which end of the differenti...

Page 11: ...ng gear mounting face shown as A in Figure 2 and record this measurement as A Measure the thickness of the factory shim removed from the end of the differential carrier shown as B in Figure 2 and record this measurement as B Figure 3 Measure the distance from the Air Locker bearing shoulder to the ring gear mounting face shown as C in Figure 3 and record this measurement as C RING GEAR FLANGE AIR ...

Page 12: ...surement for D in Figure 3 Use the following calculation A B C D Replacement Shim Pack HINT If your calculations are correct then the following calculation will also be true A B C D ZERO Create a shim pack to match the thickness calculated as D To achieve the desired shim thickness you can Machine down the factory shim thickness Add shims between the factory shim and the bearing cup HINT A selecti...

Page 13: ... facilitate assembly NOTE NEVER HEAT GEARS WITH A FLAME This could damage the hardened surface of the gear and result in premature wear or failure Dry the gear and bolt holes with compressed air if wet Install the ring gear onto the Air Locker by aligning the bolt holes and then gently tapping it around in a circle with a soft mallet Avoid using the bolts to pull down the ring gear as this puts ex...

Page 14: ... gear flange of the differential carrier As shown in Figure 4 until the bearing seats firmly against the bearing journal shoulder Figure 4 Invert the Air Locker and press the second bearing cone onto the bearing journal on the ring gear flange side of the differential the seal housing side until the bearing seats firmly against the bearing journal shoulder NOTE Never re use any bearings which are ...

Page 15: ...ess press the appropriate bearing cup into the bottom of the same bearing bore i e until it stops against the shim pack HINT You should not be able to rotate the shim pack underneath the bearing cup if it has been pressed in far enough With the deep half of the clamshell sitting firmly on a horizontal surface set the Air Locker into the bearing cup inside the clamshell Bend the seal housing tube s...

Page 16: ...s against the seal housing Carefully assemble the shallow half of the clamshell over the top of the Air Locker Measure the preload gap that exists between the two halves of the clamshell housing with a feeler gauge Refer to Fig 6 Figure 6 NOTE The preload gap should be the same when measured all the way around the housing If this is not true then reposition the shallow clamshell half and re measur...

Page 17: ...he specified preload amount to the end float measurement determined with the feeler gauge to determine a shim amount for E Refer to Figure 5 PRELOAD END FLOAT SHIM PACK Create a shim pack E to closely match the measured amount NOTE Do not add shims between the bearing cone and the bearing seat and NEVER machine the Air Locker 3 7 Drilling Tapping the Bulkhead Port A port must be drilled and tapped...

Page 18: ...t vertical position of the drilled hole measure down from the machined face shown at the top of the picture in Figure 8 a distance of 13 5mm 17 32 and mark the horizontal line which the hole is centered on Then refer to Figure 9 for the correct position on that line to start drilling ...

Page 19: ...fully remove the rag and inspect with a service light inside the clamshell to insure no metal filings are left behind 3 8 Installing the Seal Housing Sit the seal housing on top of the shallow clamshell half Without using sharp jagged tools such as pliers usually your hands are the best tool for this job gently bend the seal housing tube so that it lines up with the bulk head fitting hole as shown...

Page 20: ...areful not to leave them twisted when seated in the grooves as this could cause excessive wear and leakage Assemble the shim pack and seal housing E in Figure 5 into the bearing bore of the shallow half of the clamshell Position the seal housing so that the end of the seal housing tube goes through the center of the bulkhead port hole Refer to Figure 11 Figure 11 Using a bearing press or arbor pre...

Page 21: ...de of the housing assemble one of the small O rings over the top of the short length of seal housing tube protruding through the bulkhead fitting Install the brass spacer Install the second small O ring after the spacer While holding the seal housing tube into the bulkhead fitting insert the chamfered end of the center compression nut over the extended tube as shown in the assembly diagram Fig 12 ...

Page 22: ...ly Carefully assemble the deep half of the clamshell over the top of the Air Locker Bolt the clamshell assembly closed Check that some backlash can be felt between the ring and pinion gears No backlash would be an early indication of incorrect shim thickness The seal housing tube needs to be carefully bent so that it will stay clear of any moving parts of the differential and not rub against any s...

Page 23: ...lat screwdriver or pry bar through one of the axle stub holes so that it wedges between the cross shaft and the carrier body so that the differential center can be rotated by the cross shaft not by the spline of one of the differential gears While supporting the pinion gear by holding the drive shaft flange rotate the differential in both directions with the screwdriver or pry bar while observing ...

Page 24: ...of the clamshell Remove the center compression nut from the bulkhead fitting Fig 12 Pull the seal housing tube free of the bulkhead fitting NOTE This may require rotating the seal housing slightly Using an arbor press or bearing press press out the seal housing assembly and the bearing cup from the deep half of the clamshell To decrease the amount of backlash reduce the shim thickness D Fig 3 and ...

Page 25: ...ect the air hose and watch to see if there is any drop in pressure If so this will indicate an air leak Figure 14 If a leak is found to be present spray a soap and water mixture onto the bulkhead air fitting Bubbles should appear at any leak points NOTE Do not spray this soapy mixture inside the differential Check that leaky fittings have been adequately tightened Disassemble clean threads and rea...

Page 26: ...d be snug and light tapping may be required to fully insert the stubs into the splines In some cases a small chamfer may need to be ground onto the axle stubs as a lead in for insertion into the bushings Install the differential assembly into the vehicle Insert both CV axles completely into the housing and gently tap them inward until the retaining clips have seated NOTE Be careful not to damage o...

Page 27: ...nk NOTE The coil and stem of the solenoid can be removed to make installation easier NOTE The solenoid is marked with two 1 ports If space is tight a second solenoid can be daisy chained off the first one by removing the plug from the redundant 1 port and screwing the nipple from the second solenoid into it Fig 15 NOTE The solenoid exhausts compressed air through the center of the black retaining ...

Page 28: ...at you have the necessary capacity is to make sure you can engage disengage and then reengage your Air Locker s without the air source having to regenerate e g without the compressor turning on to refill the tank Must supply clean air free of rust dirt water or other foreign matter Must match the 1 8 BSP porting of the Air Locker solenoid Mount solenoid within close proximity of the air supply and...

Page 29: ...does not contact sharp edges or abrasive surfaces that may damage the air line over time Do not run the air line around tight bends which may kink the air line and restrict or block the air flow Keep the air line well away from your vehicle s exhaust components Air lines will melt if subjected to extreme heat Do not run more air line than necessary Excess line volume created when coiling the left ...

Page 30: ...n fitting body and screw into the banjo fitting Tighten using a 12mm spanner Insert the outer compression nut and ferrule over the air line Ferrule should be orientated as per Fig Error Reference source not found Figure 16 Push the airline into the compression fitting body and screw the outer nut down onto it Using a 12mm spanner tighten the outer nut onto the compression fitting body NOTE Some fo...

Page 31: ...4 Installing the Air System 29 NOTE When right angle routing of the tube is not required screw the compression fitting body straight into the bulkhead fitting body Fig Error Reference source not found ...

Page 32: ...Air Locker switch should be able to be operated without physical effort or distraction to the driver Switch es should be mounted within the line of sight of the driver so that switch position ON or OFF can be visually determined by the rocker position and the illumination state The position of the switch es should best eliminate any possibility of accidental operation by the driver or one of the p...

Page 33: ...hen wiring the Air Locker actuator switch es and solenoid s to an ARB Air Compressor all connections can easily be set up directly from the supplied wiring loom Fig 18 NOTE 180409 model loom shown for reference only Refer to your ARB Air Compressor Installation Guide for details on configuring your installation Figure 18 ...

Page 34: ... the vehicle 5 2 2 1 Single Air Locker System If only one Air Locker is to be installed in the system the switch and solenoid should be wired according to Figure 20 regardless of whether the Air Locker has been installed in the front or rear axle of the vehicle Attach the appropriate switch cover i e FRONT or REAR to the switch NOTE Refer to Figure 19 for the correct switch terminal identification...

Page 35: ...ration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on Attach the REAR AIR LOCKER switch cover to SWITCH 1 and the FRONT AIR LOCKER switch cover to SWITCH 2 NOTE Refer to Figure 19 for the correct switch terminal identification and switch orientation Configure SOLENOID 1 as the air line leading to the rear axle Air Locker and SOLENOID 2 as the air line leading to the front axle A...

Page 36: ... to be present spray a soap and water mixture onto all air fittings in the system while the compressor is fully charged Bubbles should appear at any leak points Check that leaky fittings have been adequately tightened Disassemble clean threads and reapply thread sealant if leaking persists 6 2 Testing the Air Locker Actuation To test that your air system electrical system and your Air Locker diffe...

Page 37: ...e Sealing Filling the Differential NOTE Consult the ARB Air Locker Operating Service Manual for recommendations on differential lubricant specifications Refill the differential until level with the filler hole Rotate the differential center 2 full turns Check the oil level and refill if necessary Replace filler plug apply thread sealant to filler plug before inserting if it is a threaded type plug...

Page 38: ...en filled to the correct level All air lines and wiring have been securely cable tied to resist snagging Switch es have been securely mounted within operator reach yet well away from danger of accidental engagement Switch es function correctly and illuminate to indicate that Air Locker s have been engaged The Air Locker Warning Sticker has been located within close proximity of the actuator switch...

Page 39: ...6 Testing Final Assembly 37 ...

Page 40: ......

Page 41: ...erleaf Figure 22 7 2 Specifications RD111 Toyota 8 IFS 53mm BRNG Axle Spline 30 tooth Ø33mm 1 31 Ratio Supported 3 91 1 up Ring Gear ID 126 0mm 4 96 Ring Gear OD 200mm 8 Ring Gear Bolts 10 bolts on Ø160mm 6 30 Ring Gear Torque 95Nm 70 ft lb Backlash 0 15 0 25mm 0 006 0 010 ...

Page 42: ...3SP 20 2 ANTI FRICTION BUSHING PTFE 160804SP 1 BULKHEAD FITTING KIT BANJO TYPE 170114 4 1 NYLON AIR LINE 6mm DIA X 6m LONG 170314SP 4 1 SOLENOID VALVE 12V 180103 1 SWITCH FR LOCKER 180223 1 CABLE TIE PK OF 25 180305 1 OPERATING SERVICE MANUAL 210200 1 INSTALLATION GUIDE 2102111 Not illustrated in exploded view NOTES 1 For replacement O rings use only BS136 Viton 75 2 Available only as complete 6 g...

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