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Table of Contents:

1 Introduction

1.1

Pre-Installation Preparation

1.2

Tool-Kit Recommendations

1.3

Assembly Type Identification

2 Removing the Existing Differential

2.1

Vehicle Support

2.2

Differential Fluid Drain

2.3

Disconnecting the Axles

2.4

Marking the Bearing Caps

2.5

Checking the Current Backlash Amount

2.6

Removing the Differential Center

3 Installing the Air Locker

3.1

Insuring Adequate Oil Drainage

3.2

Installing the Carrier Bearings

3.3

Approximate Backlash Shimming

3.4

Mounting the Ring Gear

3.5

Drilling and Tapping the Bulkhead Port

3.6

Assembling the Seal Housing

3.7

Pre-Load Shimming

3.8

Reinstalling the Bearing Caps

3.9

Checking the Backlash

3.10

Setting Up the Bulkhead Fitting

3.11

Profiling the Seal Housing Tube

4 Installing the Air System

4.1

Mounting the Solenoid

4.2

Running & Securing the Air Line

4.3

Connection to the Bulkhead Fitting

5 Mounting & Connecting the Electrical System

5.1

Mounting the Actuator Switch(es)

5.2

Wiring the Actuator System

6 Testing & Final Assembly

6.1

Leak Testing

6.2

Reinstalling the Axles

6.3

Testing the Air Locker Actuation

6.4

Re-Sealing & Filling the Differential

6.5

Post-Installation Check List

7 Parts List

7.1

Exploded Assembly Diagram

7.2

Itemized Parts List

Содержание RD101

Страница 1: ...RD101 DANA 30 27 SPLINE 3 54 DOWN AIR OPERATED LOCKING DIFFERENTIAL INSTALLATION GUIDE ...

Страница 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...

Страница 3: ... Tapping the Bulkhead Port 17 3 6 Assembling the Seal Housing 19 3 7 Pre Load Shimming 20 3 8 Reinstalling the Bearing Caps 25 3 9 Checking the Backlash 26 3 10 Setting Up the Bulkhead Fitting 27 3 11 Profiling the Seal Housing Tube 29 4 Installing the Air System 30 4 1 Mounting the Solenoid 30 4 2 Running Securing the Air Line 32 4 3 Connection to the Bulkhead Fitting 33 5 Mounting Connecting the...

Страница 4: ...2 ...

Страница 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...

Страница 6: ...e 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 Supplies ...

Страница 7: ...ousing Refer to Fig 1 B the live axle Salisbury type with a cast iron housing Refer to Fig 2 To eliminate confusion you should identify which figure your vehicle matches with The section numbers within the guide that refer ONLY to the IFS type have been suffixed with an A and those that refer ONLY to the live axle type have been suffixed with a B PLEASE IGNORE ALL SECTIONS WHICH DO NOT APPLY TO YO...

Страница 8: ... worn bearing or differential component 2 2 1 A IFS Fluid Drain Remove any skid plates covering the bottom of the front axle area and position a fluid drain reservoir under the differential Remove the threaded drain plug and completely drain all differential oil from the housing Finger tighten the drain plug back in to prevent drips during the removal of the axle assembly 2 2 2 B Live Axle Fluid D...

Страница 9: ...sembly from the vehicle Secure the differential assembly to a work bench Remove the front access cover plate 2 3 2 B Live Axle CV Shafts 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 r...

Страница 10: ...which cap is RIGHT which way is UP and which way is DOWN Fig 3 HINT Many installers choose to make one punch mark on the left hand side of the left hand bearing cap and one similar punch 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 3 ...

Страница 11: ...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 4 Figure 4 While supporting the pinion gear by hol...

Страница 12: ...l be important to match them to their original positions for measurements later NOTE The differential center is heavy and quite difficult to handle when covered in oil Take care not to drop it 2 6 2 B Cast Iron Housings IMPORTANT YOU MUST SPREAD THE HOUSING ON CAST IRON MODELS Spreading the differential housing with a differential case spreader is a step which is critical to set up bearing pre loa...

Страница 13: ...ame from which side Once the housing has been adequately spread the differential may be removed by pulling forward on the differential carrier Figure 5 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 ...

Страница 14: ...id 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 6 Figure 6 If no drainage slot is present at the le...

Страница 15: ... one of the bearing cones supplied with the Air Locker kit onto one bearing journal of the Air Locker refer to Figure 7 until the bearing seats firmly against the bearing journal shoulder Figure 7 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 NOT...

Страница 16: ...opper hammer tap in a circle around the ring gear to separate it from the differential carrier Figure 8 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 from the shoulder of the outer face of the bearing...

Страница 17: ...pack B should not be installed at this time Figure 9 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...

Страница 18: ...ore installation will remove any high spots around the threads Heat the ring gear to 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 on...

Страница 19: ... gears 3 5 1 A Port Location on the IFS KJ Housing Mark a spot on the top of the outside shell of the differential housing on the thick section of the large external rib of the housing as shown in Figure 10 Figure 10 Cover the drive pinion and axle tube areas with a rag to protect them from metal filings Drill through the housing square to the outside surface using a 11 2mm 7 16 drill Tap the hole...

Страница 20: ... through the differential housing Figure 11 Cover the drive pinion and axle tube areas with a rag to protect them from metal filings Drill through the housing square to the outside surface using a 11 2mm 7 16 drill Tap the hole from the outside using a NPT pipe tap Figure 12 Figure 12 Remove any sharp edges from the hole that may chip off and fall into the housing Carefully remove the rags and ins...

Страница 21: ...hen 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 the 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 the stepped face of the seal housing with the rounded edge of the shim facing out NOTE No shims ot...

Страница 22: ...he right hand bearing cup in place insert and hold the Air Locker into the differential housing Insert one of the two master shims from the Air Locker shim kit between the right hand bearing cup and the bearing seat of the axle housing with the rounded edge of the master shim facing away from the center Insert the shim pack determined earlier as B between the bearing cup right hand side and the ma...

Страница 23: ...Figure 13 PRE LOAD END FLOAT SHIM PACK Create a shim pack D from the shims supplied with your Air Locker NOTE Do not add shims between the bearing cone and the bearing seat of the Air Locker and NEVER machine the Air Locker Remove the factory shim from the left hand side Install the shim pack D between the master shim and the seal housing as shown in Figure 13 Rotate the seal housing until the tub...

Страница 24: ...uminum differential housing Fig 17 Figure 17 NOTE Do not spread the housing on the aluminum models 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 Check that some backlash can be felt between the ring and pinion gears No backlash would be an early indication of incorrect shim thi...

Страница 25: ...cker into the differential housing Insert the remaining ARB master shim from the Air Locker shim kit between the right hand bearing cup and the bearing seat of the axle housing with the rounded edge of the master shim facing away from the center Insert the shim pack determined earlier as B between the bearing cup right hand side and the ARB master shim Push or lightly pry the Air Locker hard acros...

Страница 26: ...e 13 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 spreader tension may need to be increased Do not spread the housing more than 0 50mm 0 020 Rotate the seal housing until the tube is positioned in the center of the oil drainage notch of the axle housing Fig 19 Figure 19 Relea...

Страница 27: ...ng tube should lay 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 T...

Страница 28: ...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 21 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...

Страница 29: ...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...

Страница 30: ...ing of the center compression nut is not necessary to form a good seal around the tube and may damage the O ring 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 ...

Страница 31: ...ally 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 23 Figure 23 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 ...

Страница 32: ...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...

Страница 33: ...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 ...

Страница 34: ...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...

Страница 35: ...ng In the case of an IFS axle assembly or in the case that the 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 25 Insert the outer compressio...

Страница 36: ...mpression 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 ...

Страница 37: ... 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 ...

Страница 38: ...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 27 NOTE Refer to your ARB Air Compressor Installation Guide for details on configuring your installation ...

Страница 39: ...5 Mounting Connecting the Electrical System 37 UP Figure 27 Figure 28 SWITCH TERMINAL IDENTIFICATION ARB AIR COMPRESSOR WIRING LOOM ...

Страница 40: ...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 29 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 28 for the correct switch terminal id...

Страница 41: ...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 28 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...

Страница 42: ...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 ...

Страница 43: ...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...

Страница 44: ...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...

Страница 45: ...7 Parts List 43 7 1 Exploded Assembly Diagram See itemized parts list overleaf Figure 31 ...

Страница 46: ...PRING 150107 14 1 SPLINED SIDE GEAR 728J011 15 2 SHORT CROSS SHAFT 061402 16 4 PINION GEAR 728J011 17 4 PINION THRUST WASHER 151112 18 2 SIDE GEAR THRUST WASHER 151011 19 1 DIFFERENTIAL CASE 013103 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 ...

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