ARB Airlocker RD161 Installation Manual Download Page 1

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RD161

DANA 60, SALISBURY,

24 SPLINE, 3.54:1

AIR OPERATED

LOCKING DIFFERENTIAL

INSTALLATION GUIDE

Summary of Contents for Airlocker RD161

Page 1: ...RD161 DANA 60 SALISBURY 24 SPLINE 3 54 1 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: ...using 17 3 6 Pre Load Shimming 18 3 7 Reinstalling the Bearing Caps 20 3 8 Checking the Backlash 21 3 9 Setting Up the Bulkhead Fitting 22 3 10 Profiling the Seal Housing Tube 24 3 111 Bench Testing the Air Locker 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: ...orque 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 2 A 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 1 2...

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: ...e 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 which cap is RIGHT which way is UP...

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: ...ential 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 know which cup came from which ...

Page 11: ...ting Differential 9 NOTE The differential center is heavy and quite difficult to handle when covered in oil Take care not to drop it Relieve any tension on the spreader immediately after the differential has been removed ...

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: ... pre load and ring and pinion backlash in your Air Locker to that of your original differential measurements need to be taken so that a shim thickness can be calculated Secure the original differential to a work bench Remove the bolts that 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 Figure 5 Assemble...

Page 14: ...770001 Inspect the bearings for wear or damage and replace if necessary Apply a thin film of high pressure grease to both bearing journals of the Air Locker to prevent seizing Using a bearing press or arbor press press one of the bearing cones onto one bearing journal of the Air Locker refer to Figure 6 until the bearing seats firmly against the bearing journal shoulder NOTE Do not add any shims b...

Page 15: ...and added later Figure 7 Record this measurement as C The thickness of the shim pack B should make the distance C on the Air Locker closely match the distance A on the existing differential within 0 1mm 0 004 Use the following calculation to find the desired thickness of B A C B Replacement Shim Pack HINT If your calculations are correct then the following equation will also be true A B C ZERO ...

Page 16: ... If necessary shim kit B can be made from the standard Dana shims not supplied and put between the bearing cone and bearing seat Place this shim pack on 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 on the original differential NOTE NEVER machine the Air Locker ...

Page 17: ... 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 18: ...rential housing in either of the positions shown in Figure 8 Choose the position that is more suited to giving maximum clearance around the bulkhead fitting 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 ...

Page 19: ... 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 With the stepped side towards the bearing carefully install the seal housing by sliding it all of the way onto the be...

Page 20: ... gap also called the end float between the outside of the seal housing and the inside face of the axle housing with an automotive feeler gauge Fig 10 Figure 10 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 D...

Page 21: ...ction 2 6 Re install the Air Locker into the axle housing NOTE If the Air Locker is too tight to fully install then the spreader tension may need to be increased Do not spread the housing more than 0 50mm 0 020 NOTE Use the ARB Shim Driver 0770004 to install the supplied Air Locker shims Rotate the seal housing until the tube is pointing straight out of the axle housing Release all spreader tensio...

Page 22: ... 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 cap bolts with a torque wrench to the torque specified in your vehicle manufacturer s service manual ...

Page 23: ... 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 3 8 1 Re Shimming the Backlash NOTE This step is only necessary when adjusting for incorrect backlash Remove the bearing caps ...

Page 24: ...ximate shape Fig 12 and trim to length using an automotive tube cutter 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 protruding through the bulkhead fitting While still holding the seal housing tube into...

Page 25: ...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 26: ...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 14 Figure 14 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 27: ...ct the air hose and watch to see if there is any drop in pressure If so this will indicate an air leak Fig 15 Figure 15 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 a...

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 17 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: ...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 19 NOTE 180409 model loom shown for reference only 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 19 Figure 20 SWITCH TERMINAL IDENTIFICATION ...

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 21 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 20 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 20 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 23 ...

Page 42: ...RN SPRING 150107 14 1 SPLINED SIDE GEAR 728K081 15 2 SHORT CROSS SHAFT 061601 16 4 PINION GEAR 728K081 17 4 PINION THRUST WASHER 151113 18 2 SIDE GEAR THRUST WASHER 151007 19 1 DIFFERENTIAL CASE 013206 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 180...

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ARB Airlocker RD161, Installation Manual

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