ARB RD246 Step Easy Installation Instructions Download Page 1

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RD246

DANA M210/M220, JEEP JL

RUBICON, 35 SPL

AIR OPERATED

LOCKING DIFFERENTIAL

INSTALLATION GUIDE

Summary of Contents for RD246

Page 1: ...RD246 DANA M210 M220 JEEP JL RUBICON 35 SPL 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: ...5 Installing the Carrier Bearings 18 3 6 Mounting the Ring Gear 18 3 7 Preload Shim Measurement 20 3 8 Setting up the Bulkhead Fitting 22 3 9 Profiling the Seal Housing Tube 24 3 10 Bench Testing the Air Locker 25 3 11 Reinstalling Differential and Axles 26 4 Installing the Air System 27 4 1 Mounting the Solenoid 27 4 2 Running Securing the Air Line 29 4 3 Connection to the Bulkhead Fitting 30 5 M...

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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: ...tubing A torque wrench See your vehicle service manual for the required torque range A lubricant drain reservoir 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 suitable shim driver e g ARB Shim Driver 0770004 A slide hammer A bearing press or arbor press 1 2 2 Supplies Thread l...

Page 7: ...custom aftermarket 35 spline axle shafts JL Rubicon Models The RD246 can be used in JL Rubicon models but requires aftermarket electronics not supplied by ARB It CANNOT be used in rear only applications It CAN be used in front only applications or front AND rear applications but requires a programmer to modify the ECU These Air Lockers also require custom aftermarket 35 spline axle shafts Contact ...

Page 8: ... 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 9: ...turer s service manual IMPORTANT Collision damage or heavy off road use of your vehicle in the past may have resulted in some degree of bending in the axle Any misalignment of the axle tubes may result in excessive wear and or failure of your differential and axle shafts ARB strongly recommends that you have your axle assembly inspected for concentricity and straightness before installing your Air...

Page 10: ...FT and which cap is RIGHT which way is UP and which way is DOWN Fig 1 HINT Many installers choose to make one punch mark on the left hand side of the left hand bearing cap and a similar mark on the housing at close proximity to the cap mark The right hand side is then designated with two punch marks on the right hand side of the cap and two similar punch marks on the housing Figure 1 ...

Page 11: ...d you set backlash according to your service manual guidelines we also advise that you compare the backlash measurements taken here to the recommended backlash settings in your vehicle service manual 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 ve...

Page 12: ...fferential case spreader is a step which is critical to set up bearing pre load on cast iron differential housings See Figure 3 Improper pre load will result in undue bearing wear increased 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 ...

Page 13: ...Differential 11 Figure 3 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 14: ...ugh the differential housing to mount the bulkhead fitting into Cover the drive pinion and axle tube areas with a rag to protect them from metal filings Mark a spot on the right hand side of the differential in a position that will be clear of the ring gear and Air Locker once the seal housing is installed Fig 4 6 Figure 4 ...

Page 15: ...order to reproduce a similar preload and ring and pinion backlash in your Air Locker to that of your existing differential measurements need to be taken so that a shim thickness can be calculated Secure the differential to a workbench 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 ...

Page 16: ...ly accurate measurement method i e able to take accurate measurements within 0 04mm 0 0015 measure the distance from the shoulder of the bearing journal to the ring gear mounting face shown as A in Figure 7 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 7 and record this measurement as B FACTORY DIFFE...

Page 17: ... the Air Locker 15 Figure 8 Measure the distance from the Air Locker bearing shoulder to the ring gear mounting face shown as C in Figure 8 and record this measurement as C RING GEAR FLANGE AIR LOCKER DIFFERENTIAL ...

Page 18: ...surement for D in Figure 8 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 19: ...rously lubricate the O rings with oil prior to assembly then insert them into the 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 Carefully install the seal housing by sliding it all of the way onto...

Page 20: ...ing gear shoulder of the Air Locker to prevent seizing Thoroughly clean any thread locking compound or other foreign matter from the holes of the ring gear the threads of the ring gear bolts the mating surfaces of the ring gear and the Air Locker flange HINT Rubbing the ring gear mounting face with a flat oil stone before installation will remove any high spots around the threads Heat the ring gea...

Page 21: ... the ring gear down as this puts excess strain on the bolts and the differential flange Apply a thread locking compound to the thread of each ring gear bolt before inserting it Do not apply locking compound directly into the threaded hole as this could prevent the bolt from reaching its full depth NOTE On some models the crown wheel bolts cannot be reused and should therefore be replaced Refer to ...

Page 22: ...y the Air Locker hard across to the right hand side and measure the gap also called the end float between the bearing cup and the housing with a feeler gauge See Fig 12 Record this measurement Consult your vehicle manufacturer s service manual to determine the carrier bearing preload amount specified for your vehicle NOTE If your service manual specifies preload in terms of a torque value measured...

Page 23: ...ss you can Machine down the factory shim thickness Add shims between the factory shim and the bearing cup Purchase new factory shims at the desired thickness Use a universal shim kit available from most drive train specialists NOTE Do not add shims between the bearing cone and the bearing seat and NEVER machine the Air Locker Assemble the seal housing bracket onto the left hand bearing cap align w...

Page 24: ... sealant inside and outside of the housing Without using sharp jagged tools such as pliers your hands are the best tool for this job bend the seal housing tube to approximate the finished profile This will allow the tube to be trimmed to a length that would allow it to protrude from the bulkhead fitting Fig 13 NOTE Use an automotive brake line tubing cutter to cut the seal housing tube Never a hac...

Page 25: ...e 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 14 and screw it into the bulkhead body and tighten using Pozidriv 3 screwdriver Figure 14 NOTE Make sure the seal housing tube is all of the way into the cente...

Page 26: ...e Seal Housing Tube With the seal housing tube now firmly secured into the bulkhead fitting bend the tube so that it closely follows the profile of the differential without interfering with the bearing cap diff housing or Air Locker Fig 15 Figure 15 ...

Page 27: ... until 620 KPA 90 PSI is reached shut the valve off disconnect the air hose and watch to see if there is any drop in pressure Any gradual pressure drop indicates an air leak Fig 16 Figure 16 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 le...

Page 28: ...Axles Install the axles and cover plate as detailed in your vehicle service manual NOTE Be careful not to damage the axle shaft oil seals when installing the axle Support the axle s entire weight where possible Torque down the axle bolts to manufactures specifications ...

Page 29: ...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 17 NOTE The solenoid exhausts compressed air through the center of the black retaining ...

Page 30: ...hat 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 an...

Page 31: ...is 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 that 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 ...

Page 32: ...line to length using a sharp knife Assemble an aluminium washer onto the banjo bolt and insert through the banjo fitting Assemble second aluminium washer and tighten into bulkhead fitting using a 14mm 9 16 spanner Fig 18 Apply thread sealant to the tapered thread of the compression fitting body and screw into the banjo fitting Tighten using a 12mm spanner Insert the outer compression nut and ferru...

Page 33: ...compression fitting body NOTE Some force is required to crush the ferrule however the outer compression nut will tighten against a stop Over tightening will not create a better seal Secure any loose sections of tube with a cable tie NOTE When right angle routing of the tube is not required screw the compression fitting body straight into the bulkhead fitting body Fig 18 ...

Page 34: ...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 35: ...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 20 NOTE 180409 model loom shown for reference only Refer to your ARB Air Compressor Installation Guide for details on configuring your installation Figure 20 ...

Page 36: ... 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 identification...

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: ...or the air system will have to be leak tested with a pressure gauge and a shut off valve in series before the solenoid input Fig 16 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 tightened Disassemble clean threads and re...

Page 39: ...te 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 3 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 fu...

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: ...icon 35 SPL Axle Spline 35 tooth Ø38 1mm 1 50 Ratio Supported All Ring Gear ID 134 66mm 5 302 Ring Gear OD Front 210 00mm 8 267 Rear 220 00mm 8 661 Ring Gear Bolts 10 bolts on Ø157 8mm 6 213 Ring Gear Torque Front 136Nm 100 ft lb Rear 210Nm 155 ft lb Backlash 0 12 0 18mm 0 003 0 005 Bearing Cap Torque Front 108Nm 80 ft lb Rear 95Nm 70 ft lb ...

Page 42: ...6 1 SHIM KIT SHK001 17 TAPERED ROLLER BEARING NOT SUPPLIED 18 1 SEAL HOUSING KIT 082101SP 19 1 SEAL HOUSING O RINGS PK OF 2 160233SP 1 20 1 BONDED SEAL 160702SP 21 1 SPLINED SIDE GEAR SEE NOTE 2 22 1 SPIDER BLOCK 070201SP 1 BULKHEAD FITTING KIT BANJO TYPE 170114 1 AIR LINE 6mm DIA X 6m LONG 170314SP 1 SOLENOID VALVE 12V 180103 1 SWITCH 180209SP 1 SWITCH COVER REAR 180211SP 1 SWITCH COVER FRONT 180...

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ARB RD246, Step Easy Installation Instructions

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