ARB Airlocker RD158 Installation Manual Download Page 1 | Manualshive

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RD158

DANA 50, 30 SPLINE

AIR OPERATED

LOCKING DIFFERENTIAL

INSTALLATION GUIDE

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Summary of Contents for Airlocker RD158

Page 1: ...RD158 DANA 50 30 SPLINE 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: ...bling 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 Connect...

Page 4: ......

Page 5: ...our 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 experience a...

Page 6: ...ehicle manual for required torque range A lubricant drain reservoir Suitable measuring tools to measure a differential for pre load and or backlash shimming e g automotive feeler gauge See Section 4 5 An 11 2mm 7 16 drill and NPT tap for bulkhead fitting installation An automotive bearing puller e g ARB Bearing Puller 0770001 or a differential carrier bearing puller A bearing press or arbor press ...

Page 7: ...on your drain plug or in the 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 If a drain plug exists remove it and completely drain all differential oil from the housing If no drain plug exists then the oil can be dra...

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: ...ge Unbolt and remove both bearing caps from the differential housing HINT Be sure not to mix up the left and right hand bearing cups Later it will be necessary to know which cup came from which side 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 Once the housing has been adequa...

Page 11: ...t hold 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 Remove the original bearings from the differential center using a bearing puller Fig 4 NOTE Keep the bearings and shims separated so that they can be identified as to which end of the differential they came from Examine the bearing cups and cones from Fig...

Page 12: ...g journal to the ring gear mounting face shown as A in Fig 5 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 Fig 5 and record this measurement as B Measure the distance from the Air Locker bearing shoulder to the ring gear mounting face shown as C in Fig 6 and record this measurement as C AIR LOCKER DIFFERENT...

Page 13: ...ack thickness by using the measurements you recorded earlier to find a desired measurement for D in Fig 6 Use the following calculation A B C D HINT If your calculations are correct then the following equation will also be true A B C D ZERO To make a shim pack to match the measurement you calculated as D you can Select shims from the shim kit supplied with your Air Locker kit Purchase a new shim k...

Page 14: ...ng cones onto one of the bearing journals of the Air Locker until the bearing seats firmly against the bearing journal shoulder Fig 7 NOTE Never re use any bearings which are damaged or worn Invert the Air Locker and press the second bearing cone onto the opposite bearing journal until the bearing seats firmly against the bearing journal shoulder Figure 7 NOTE Do not add any shims between the bear...

Page 15: ...TH A FLAME This could damage the hardened surface of the gear and result in premature wear or failure Dry the ring gear with compressed air if wet paying particular attention to the threaded holes Install the ring gear onto the Air Locker by aligning the holes in the flange with the tapped holes in the ring gear then gently tapping it around in a circle with a plastic or copper hammer NOTE Avoid u...

Page 16: ...that will be well clear of the ring gear the differential and any other obstructions that may snag the seal housing tube Cover the drive pinion and axle tube areas with a rag to protect them from metal filings Figure 8 Drill through the housing square to the outside surface using an 11 2mm 7 16 drill Fig 8 Tap the hole from the outside using a NPT tapered pipe thread tap Remove any sharp edges fro...

Page 17: ... metal fillings etc Place the bearing cup over the bearing cone then ARB master shim over the cup Figure 9 Generously lubricate the O rings with oil prior to assembly then insert them into the grooves of the seal housing With a slight twisting motion carefully slide the seal housing all the way onto the bearing journal NOTE The shim pack cannot be installed at this time as the required thickness s...

Page 18: ...easurement determines the shim thickness necessary to achieve neutral pre load Adding more shim than this measurement becomes the actual pre load Consult your vehicle manufacturer s service manual to determine the carrier bearing pre load amount specified for your vehicle Add the specified pre load amount to the measurement taken with the feeler gauge to determine a shim amount for E in Figure 9 P...

Page 19: ...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 20: ...value is referred to as the ring and pinion backlash Rotate the differential center 90 and measure again for accuracy Figure 11 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 will have to be removed and re shimmed 4 7 1 Re Shimming the Backlash NOTE This step is only necessary whe...

Page 21: ...ofiling the Seal Housing Tube Completely remove the differential spreader if applicable 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 runs along the inside of the differential housing as shown in Figure 12 Figure 12 NOTE It is also a good idea to keep the tube away from the bearing caps or any other pa...

Page 22: ...ess 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 O ring over the top of the short length of seal housing tube protruding through the bulkhead fitting While holding the seal housing tube into the bulkhead fitti...

Page 23: ... moving parts if necessary 4 10 Leak Testing the Air Locker To test the Air Locker when 620kPa 90 PSI shop air is applied to the seal housing tube the Air Locker should engage Check all fittings and the seal housing for air leaks Rotate the differential carrier by turning the pinion flange whilst applying air pressure NOTE An accurate way to test for air leaks is to fit a shut off valve to an air ...

Page 24: ...emove the seal housing assembly and examine the O rings Be very careful with the O rings and check for defects damage wear or presence of foreign material in the O ring grooves Replace if necessary 4 11 Reinstalling the Axles Insert both axles fully into the housing and gently tap them inward NOTE Be careful not to damage the axle oil seals with the spline of the axle Reassemble the brakes differe...

Page 25: ...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 26: ...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 27: ...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 over hose using u...

Page 28: ...way to the end Figure 16 HINT If the tube is too difficult to push on place the end of the air line into a cup of boiled water to soften the tubing 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 ...

Page 29: ... 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 30: ...mpressor 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 18 NOTE 180409 model loom shown for reference only Refer to your ARB Air Compressor Installation Guide for details on configuring your installation ...

Page 31: ...6 Mounting Connecting the Electrical System 29 UP Figure 18 Figure 19 SWITCH TERMINAL IDENTIFICATION ...

Page 32: ...installed in the vehicle 6 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 id...

Page 33: ...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 34: ...an air cylinder or a belt 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...

Page 35: ...e wheel again Both wheels should rotate together Turn the switch off again Rotate the same wheel The wheels should again rotate in opposite directions 7 3 Re Sealing Filling the Differential NOTE Consult the ARB Air Locker Operating Service Manual for recommendations on differential lubricant specifications Install the differential cover using gasket sealant or a new standard differential gasket f...

Page 36: ...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 37: ...8 Parts List 35 8 1 Exploded Assembly Diagram See itemized parts list overleaf Figure 22 ...

Page 38: ...GS 160207 13 8 RETURN SPRINGS 150113 14 1 SPLINED SIDE GEAR 728H081 15 1 LONG CROSS SHAFT 060204 16 1 SPIDER BLOCK 070201 17 8 PINION GEARS 728H081 18 4 PINION THRUST WASHER 151110 19 1 DIFFERENTIAL CASE 013036 1 BULKHEAD FITTING KIT O RING TYPE 170111 1 PUSH IN FITTING 5mm to 1 8 BSPP 170201 1 AIR LINE 5mm DIA X 6m LONG 170301 1 SOLENOID VALVE 12V 180103 1 SWITCH 180209 1 SWITCH COVER FRONT 18021...

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