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6 Testing & Final Assembly

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Summary of Contents for RD121

Page 1: ...INSTALLATION GUIDE RD121 TOYOYA 8 IFS 53mm BRNG Part No 2102121 Revision 20 09 05 Copyright 2005 by ARB Corporation Limited ...

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: ...lling Tapping 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...

Page 4: ...2 ...

Page 5: ...manual Although 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 wealt...

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

Page 7: ... differential component c Once drained reinstall the drain plug 2 3 Removing the Differential Assembly c 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 disconnecti...

Page 8: ...ur vehicle service manual or your local authorized ARB installer for more information c 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 c 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: ...fer to your vehicle manufacturer s service manual c Remove all bolts from around the outside of the clamshell c Gently pry the clamshell apart and remove the differential center c 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 ...

Page 10: ...abs used on some models will not be required on the Air Locker and may be discarded c 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 c 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 differe...

Page 11: ...g gear mounting face shown as A in Figure 2 and record this measurement as A c 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 c 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 A...

Page 12: ...urement 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 c 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 select...

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 c Dry the gear and bolt holes with compressed air if wet c 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...

Page 14: ...g gear flange of the differential carrier As shown in Figure 4 until the bearing seats firmly against the bearing journal shoulder Figure 4 c 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 a...

Page 15: ...ss 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 c With the deep half of the clamshell sitting firmly on a horizontal surface set the Air Locker into the bearing cup inside the clamshell c Bend the seal housing tub...

Page 16: ... against the seal housing c Carefully assemble the shallow half of the clamshell over the top of the Air Locker c 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 mea...

Page 17: ... 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 c 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: ...efully 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 c Sit the seal housing on top of the shallow clamshell half c 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 ...

Page 20: ...areful not to leave them twisted when seated in the grooves as this could cause excessive wear and leakage c Assemble the shim pack and seal housing E in Figure 5 into the bearing bore of the shallow half of the clamshell c 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 c Using a bearing press or arb...

Page 21: ...ide of the housing assemble the small O ring over the top of the small length of seal housing tube that can be seen inside the bulkhead fitting c While holding the seal housing tube at depth insert the small drilled end of the center compression nut over the extended tube as shown in the assembly diagram Fig 12 and screw it into the bulkhead body and tighten Figure 12 NOTE Be sure to insert the co...

Page 22: ...gently c Rotate the Air Locker a few turns to make sure it rotates freely and smoothly c Carefully assemble the deep half of the clamshell over the top of the Air Locker c Bolt the clamshell assembly closed c Check that some backlash can be felt between the ring and pinion gears No backlash would be an early indication of incorrect shim thickness c The seal housing tube needs to be carefully bent ...

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 c While supporting the pinion gear by holding the drive shaft flange rotate the differential in both directions with the screwdriver or pry bar while observin...

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

Page 25: ...ct the air hose and watch to see if there is any drop in pressure If so this will indicate an air leak Figure 14 c 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 c Check that leaky fittings have been adequately tightened c Disassemble clean threads an...

Page 26: ...e 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 c Install the differential assembly into the vehicle c 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 ...

Page 27: ...the inlet port side of the solenoid stamped with a 1 onto the nipple and hand tighten it The solenoid should be rotated into a position which 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 c Apply Teflon paste to the threads...

Page 28: ...ood 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 c Must supply clean air free of rust dirt water or other foreign matter c Must match the 1 8 BSP porting of the Air Locker solenoid c Mount solenoid within close proxi...

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

Page 30: ...of tubing between the ferrule and the end of the tube c Insert the support tube all the way into the end of the air line HINT If the support tube is too difficult to insert place the end of the air line into a cup of boiled water to soften the tubing c Insert the tube end all the way into the center compression nut c Screw on the outer compression nut and tighten The ferrule and support tube are n...

Page 31: ...r 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 c The position of the switch es should best eliminate any possibility of accidental operation by the driver or one of the p...

Page 32: ...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 RDCKA RDCKA24 model looms shown for reference only Refer to your ARB Air Compressor Installation Guide for details on configuring your installation Figure 19 RDCKA RDCKA24 ...

Page 33: ...he vehicle 5 2 2 1 Single Air Locker System c 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 c Attach the appropriate switch cover i e FRONT or REAR to the switch NOTE Refer to Figure 20 for the correct switch terminal identificati...

Page 34: ...ation allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on c 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 c 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 axl...

Page 35: ... 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 c Check that leaky fittings have been adequately tightened c 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 diff...

Page 36: ...Re Sealing Filling the Differential NOTE Consult the ARB Air Locker Operating Service Manual for recommendations on differential lubricant specifications c Refill the differential until level with the filler hole c Rotate the differential center 2 full turns c Check the oil level and refill if necessary c Replace filler plug apply thread sealant to filler plug before inserting if it is a threaded ...

Page 37: ...n filled to the correct level c All air lines and wiring have been securely cable tied to resist snagging c Switch es have been securely mounted within operator reach yet well away from danger of accidental engagement c Switch es function correctly and illuminate to indicate that Air Locker s have been engaged c The Air Locker Warning Sticker has been located within close proximity of the actuator...

Page 38: ...6 Testing Final Assembly 36 ...

Page 39: ...7 Parts List 37 7 1 Exploded Assembly Diagram see itemized parts list overleaf Figure 23 ...

Page 40: ...ED 13 1 FLANGE CAP ASSEMBLY 027308 14 1 LOCKING SIDE GEAR 131411R 15 4 PINION THRUST WASHER 151110 16 4 PINION GEAR 140701R 17 2 SHORT CROSS SHAFT 060403 18 1 SIDE GEAR 131311R 19 2 SIDE GEAR THRUST WASHER 151010 20 2 CSK SCREW 200213 21 2 ANTI FRICTION BUSHING PTFE 160804 1 NYLON AIR LINE 5mm Dia X 6m long 170301 1 BULKHEAD KIT 3 5mm O RING TYPE 170105 1 PUSH IN FITTING 5mm R1 5 1 8 170201 1 SOLE...

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