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ARB AIRLOCKER RD109, Installation Manual

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ARB AIRLOCKER RD109 Installation Manual Download Page 32

 4    Installing the Air System 

 

 

 

 

30 

 

Screw on the outer compression nut and tighten, while supporting 
the center compression nut with a 3/8” spanner. The airline is now 
attached to the center compression nut. 

 NOTE :    The outer compression nut will tighten against a stop. 

Over tightening will not create a better seal.

 

 

Assemble the support spring over the outside of the outer 
compression nut. 

 

Secure any loose sections of tube with a cable tie. 

Summary of Contents for AIRLOCKER RD109

Page 1: ...RD109 DANA 44 35 SPLINE 3 92 UP AIR OPERATED LOCKING DIFFERENTIAL INSTALLATION GUIDE ...

Page 2: ... Other 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 and South American enquiries sales arbusa com Other international enquiries exports arb com au www arb com au...

Page 3: ...ead 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...

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: ... torque wrench See vehicle service manual for required torque range A lubricant drain reservoir Suitable measuring tools to measure a differential for pre load and or backlash shimming See Section 3 3 A 11 2mm 7 16 drill and NPT tap for bulkhead fitting installation An automotive bearing puller 2 jawed is recommended or a differential carrier bearing puller A bearing press or arbor press 1 2 2 Sup...

Page 7: ... bottom of the housing which may indicate a worn bearing or differential component Clean around the differential cover plate seal to prevent dirt from entering the differential Position a fluid drain reservoir under the differential and loosen all differential cover plate retaining bolts If a drain plug exists remove it and completely drain all differential oil from the housing If no drain plug ex...

Page 8: ...al drive flange Remove both axle shafts according to your vehicle manufacturer s service manual NOTE The axle oil seals are delicate and can be easily damaged Support the weight of the axle shaft when drawing them out of their sockets in the housing 2 4 Marking the Bearing Caps Using a pointed center punch gently mark the bearing caps in a way that will enable you to know which cap is LEFT and whi...

Page 9: ...ual Measurements found to be outside of your service manual recommendations may indicate the need to deviate from those settings in order to achieve quiet running with a good contact mark Refer to your vehicle service manual or your local authorized ARB installer for more information Set a depth indicator on one of the ring gear teeth as in figure 2 Figure 2 While supporting the pinion gear by hol...

Page 10: ...eased stresses in the differential center increased running noise and ultimately ring and pinion gear damage Remove both bearing caps Carefully spread the housing Fig 3 enough to remove the differential center Refer to your vehicle s service manual NOTE Do not spread the housing more than 0 50mm 0 020 HINT Be sure not to mix up the left and right hand bearing cups Later it will be necessary to kno...

Page 11: ...ediately after the differential has been removed NOTE Some Dana 44 type differentials now come from the factory equipped with an OE master shim on the outside of each bearing cup to setup bearing preload This system is used instead of using a shim pack underneath each bearing cone Do not mix up which side of the differential the OE master shims came from as they must be re used on assembly ...

Page 12: ...d valve This is a design flaw which was corrected by most automakers in the later releases of their axle assemblies If no lower drainage point is present in the differential housing then it is critical that you modify the housing to include one Inspect the differential housing for the presence of adequate drainage in both axle tubes refer to Fig 4 Figure 4 If no drainage slot is present at the lef...

Page 13: ...ess one of the bearing cones supplied with the Air Locker kit onto one bearing journal of the Air Locker refer to Figure 5 until the bearing seats firmly against the bearing journal shoulder Figure 5 Invert the Air Locker and press the other tapered roller bearing cone onto the opposite bearing journal of the differential carrier until the bearing seats firmly against the bearing journal shoulder ...

Page 14: ...old the ring gear in place Using a plastic or copper hammer tap in a circle around the ring gear to separate it from the differential carrier Figure 6 Assemble the original bearing cup onto the cone of the right hand side of the original differential carrier Using a caliper or similarly accurate measurement method i e able to take accurate measurements within 0 04mm 0 0015 measure the distance fro...

Page 15: ...he new bearing cup and ARB master shim supplied with your Air Locker kit onto the right hand side of the Air Locker as shown in Fig 7 and measure the total distance C NOTE The shim pack B should not be installed at this time NOTE The OE master shim if present should not be included in measurement C Figure 7 Record this measurement as C ...

Page 16: ...lacement Shim Pack HINT If your calculations are correct then the following equation will also be true A B C ZERO Select shims from the shim kit supplied with your Air Locker to make the thickness B as determined above Place this shim pack between the ARB master shim and the bearing cup Re measure the new distance C from the Air Locker now including the shim pack B to make sure that it matches A o...

Page 17: ...o between 80 and 100 C 175 212 F in hot water or in an oven to slightly expand the gear and 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...

Page 18: ...rential housing that is about 40mm 1 5 in from the bolt face where the inspection cover sits and located as shown in the completed installation in Figure 8 The bulkhead position must allow the seal housing tube assembled at a later time to be clear of the ring gear position Figure 8 Cover the drive pinion and axle tube areas with a rag to protect them from metal filings Drill through the housing s...

Page 19: ... grooves of the seal housing NOTE When assembling the O rings be careful not to leave them twisted when seated in the grooves as this could cause excessive wear and leakage Lubricate the seal housing running surface on the Air Locker carrier with oil Assemble a bearing cup onto the left hand side of the Air Locker Assemble one of the two ARB master shims included with the Air Locker shim kit onto ...

Page 20: ...aster shim between the seal housing and the axle housing making sure to align the notch with the notch in the axle housing and the seal housing tube All pre load measurements and any required shimming should be made between the seal housing and the left hand OE master shim Figure 10 Insert and hold the Air Locker into the differential housing Insert the remaining ARB master shim from the Air Locke...

Page 21: ...d shims between the bearing cone and the bearing seat and NEVER machine the Air Locker Remove the Air Locker from the axle housing Install the shim pack D between the ARB master shim and the seal housing as shown in Figure 9 Spread the differential housing again Refer to Section 2 6 Re install the Air Locker into the axle housing NOTE If the Air Locker is too tight to fully install then the spread...

Page 22: ...stalling the Air Locker 20 Figure 12 Release all spreader tension Check that some backlash can be felt between the ring and pinion gears No backlash would be an early indication of incorrect shim thickness ...

Page 23: ...as low in the seal housing groove as possible Install the bearing caps oriented as they were marked before they were removed and tighten the bearing cap bolts It is not necessary to torque them down at this time Check that some clearance exists between the bearing cap and the seal housing tube If not the bearing cap should be removed and the tube re bent for adequate clearance Tighten all bearing ...

Page 24: ...erving the maximum variation in depth from the indicator i e the highest value minus the lowest value This value is referred to as the ring and pinion backlash Rotate the differential center 90 and measure again for accuracy Figure 14 Refer to your vehicle service manual for the specified maximum and minimum amounts of backlash If the backlash is not within the specifications then the differential...

Page 25: ...Bulkhead Fitting Apply thread sealant to the threads of the bulkhead body Screw the bulkhead body into the tapped hole and tighten Wipe the area clean of any excess thread sealant inside and outside of the housing Insert the free end of the seal housing tube into the bulkhead fitting until it protrudes approximately 8mm 5 16 through the other side From the outside of the housing assemble the small...

Page 26: ...center compression nut is not necessary to form a good seal around the tube and may damage the O ring the seal housing tube or the threads of the compression nut NOTE Make sure the seal housing tube is all of the way into the center compression nut while you are tightening it ...

Page 27: ...ur hands are the best tool for this job gently bend the seal housing tube so that it runs along the inside of the differential housing as shown in Figure 16 Figure 16 NOTE It is also a good idea to keep the tube away from the bearing caps or any other part of the differential casting as any contact due to vibration or shock may wear the tube and eventually cause a leak ...

Page 28: ...ble the inlet port side of the solenoid stamped with a 1 onto the nipple and tighten The solenoid should be rotated into a position that does not obstruct any other ports on the compressor tank NOTE The solenoid exhausts compressed air through the center of the black retaining cap when the Air Locker is disengaged Make sure this orifice cannot be obstructed Apply Teflon paste to the threads of the...

Page 29: ...good way to insure that 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 ...

Page 30: ...th This will save complications that may arise if the air line has to be removed Make sure the line 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 ex...

Page 31: ... axle assembly has been completely removed from the vehicle the assembly will have to be remounted in order to position the bulkhead fitting in its correct location for air line access Trim the air line to length using a sharp knife Insert the support spring over the end of the air line small end first Fig 18 Insert the outer compression nut over the air line Push the airline onto the barb on the ...

Page 32: ...sion nut with a 3 8 spanner The airline is now attached to the center compression nut NOTE The outer compression nut will tighten against a stop Over tightening will not create a better seal Assemble the support spring over the outside of the outer compression nut Secure any loose sections of tube with a cable tie ...

Page 33: ... any 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 ...

Page 34: ...ction to an ARB Air Compressor When 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 20 NOTE Refer to your ARB Air Compressor Installation Guide for details on configuring your installation ...

Page 35: ...5 Mounting Connecting the Electrical System 33 UP Figure 20 Figure 21 SWITCH TERMINAL IDENTIFICATION ARB AIR COMPRESSOR WIRING LOOM ...

Page 36: ...installed in 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 22 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 21 for the correct switch terminal id...

Page 37: ...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 21 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 38: ...elt driven air pump is used instead of a compressor the air system will have to be leak tested with a pressure gauge and a shut off valve in series before the solenoid input If a leak is found 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 ...

Page 39: ...y resistance or mechanical noise from within the differential Turn the Air Locker switch to the ON position The illuminated symbol on the switch cover should light up Rotate the same wheel again Both wheels should rotate together Turn the switch off again Rotate the same wheel The wheels should again rotate in opposite directions 6 4 Re Sealing Filling the Differential NOTE Consult the ARB Air Loc...

Page 40: ...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 properly and illuminate to indicate that Air Locker s are engaged All operators who are to use the Air Locker have read and fully understand the ARB Air Locker Oper...

Page 41: ...7 Parts List 39 7 1 Exploded Assembly Diagram See itemized parts list overleaf Figure 24 ...

Page 42: ...14 1 SPLINED SIDE GEAR 728H031 15 2 SHORT CROSS SHAFT 060403 16 4 PINION GEAR 728H031 17 4 PINION THRUST WASHER 151110 18 2 SIDE GEAR THRUST WASHER 151010 19 1 DIFFERENTIAL CASE 013004 1 BULKHEAD KIT O RING TYPE 3 5 5mm 170111 1 PUSH IN FITTING 5mm R1 5 1 8 170201 1 AIR LINE 5mm DIA X 6m LONG 170301 1 NIPPLE 1 8 BSP MALE TO MALE 170501 1 SOLENOID VALVE 180103 1 ACTUATOR SWITCH 180209 1 SWITCH COVE...

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