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ARB RD121 Installation Manuals

Air locker toyoya 8” ifs,53mm brng
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INSTALLATION GUIDE
RD121
TOYOYA 8" IFS,53mm BRNG
Part No. 2102121
Revision 20/09/05
Copyright © 2005 by ARB Corporation Limited

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Summary of Contents for ARB 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 No liability is assumed for damages resulting in the use of the information contained herein. ARB AIR LOCKER Locking Differentials and AIR LOCKER are trademarks of ARB Corporation Limited. Other product names used herein are for identification purposes only and may be trademarks of their respective owners.

  • Page 3: Table Of Contents

    Table of Contents: 1 Introduction 1.1 Pre-Installation Preparation 1.2 Tool-Kit Recommendations 2 Removing the Existing Differential 2.1 Vehicle Support 2.2 Differential Fluid Drain 2.3 Removing the Differential Assembly 2.4 Checking the Current Backlash Amount 2.5 Removing the Differential Center 3 Installing the Air Locker 3.1 Approximate Backlash Shimming 3.2 Calculation &...

  • Page 5: Introduction

    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.

  • Page 6: Tool-Kit Recommendations

    A gasket sealant or replacement gasket for your differential. c A sufficient volume of differential oil to completely refill your housing. (see the ARB Air Locker Operating and Service Manual for recommended lubricants) c A soap and water mixture to test for air leaks.

  • Page 7: Removing The Existing Differential

    2 Removing the Existing Differential Vehicle Support c Safely secure the vehicle on a hoist. We recommend supporting the vehicle on a chassis hoist to keep the differential area at a convenient working height and to leave the wheels and axles free to be rotated and removed.

  • Page 8: Checking The Current Backlash Amount

    2 Removing the Existing Differential Checking the Current Backlash Amount IMPORTANT: This step is a precautionary measure recommended by ARB due to the fact that some aftermarket ring and pinion sets have been manufactured to run with different backlash settings than those specified by your vehicle manufacturer.

  • Page 9: Removing The Differential Center

    2 Removing the Existing Differential Removing the Differential Center c Remove the floating shaft (or ADD unit if present) from the side of the differential housing. NOTE : The floating shaft or stub axle is retained by the same type of clip that was used to retain the outer stub axle. A slide hammer may be required for safe removal.

  • Page 10: Installing The Air Locker

    3 Installing the Air Locker Approximate Backlash Shimming In 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. c Secure the differential to a work bench.
  • Page 11 3 Installing the Air Locker c 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 bearing journal to the ring gear mounting face (shown as ‘A’ in Figure 2.) and record this measurement as ‘A’.

  • Page 12: Calculation & Selection Of Backlash Shims

    3 Installing the Air Locker Calculation & Selection of Backlash Shims Ideally, the measurement you recorded as ‘C’ from the Air Locker differential will closely match ‘A’ on the existing differential (within 0.1mm [0.004”] ) and then the factory shim can be reused, however, quite often these measurements will vary slightly between one factory differential and the next.

  • Page 13: Mounting The Ring Gear

    3 Installing the Air Locker Mounting the Ring Gear c Apply a thin film of high pressure grease to the ring gear shoulder of the Air Locker to prevent seizing. c Thoroughly clean any thread locking compound or other foreign matter from the holes of the ring gear, the threads of the ring gear bolts, and the mating surfaces between the ring gear and the Air Locker flange.

  • Page 14: Installing The Carrier Bearings

    3 Installing the Air Locker Installing the Carrier Bearings c Apply a thin film of high pressure grease to both bearing journals of the Air Locker. c Using a bearing press or arbor press, press one of the original tapered roller bearing cones onto the bearing journal opposite to the ring gear flange of the differential carrier (As shown in Figure 4.) until the bearing seats firmly against the bearing journal shoulder.

  • Page 15: Preload Shim Measurement

    3 Installing the Air Locker Preload Shim Measurement In order to preload the tapered roller bearings in your Air Locker, measurements need to be taken so that a value can be calculated for the total shim thickness ‘E’ in Figure 5. Figure 5.
  • Page 16 3 Installing the Air Locker c Assemble the shim pack onto the seal housing flange on the same side as the seal housing tube’s solder joint. c Assemble the seal housing into the bearing bore in the shallow half of the clamshell (shims against the clamshell). c Using a bearing press or arbor press, press the remaining bearing cup into the bottom of the same bearing bore (until it stops against the seal housing).

  • Page 17: Calculation & Selection Of Preload Shims

    3 Installing the Air Locker Calculation & Selection of Preload Shims c 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 off the drive pinion flange, then assume a preload amount of 0.25mm [0.01”] for the following calculations.
  • Page 18 3 Installing the Air Locker Figure 7. Figure 8. NOTE : To best determine the correct 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.

  • Page 19: Installing The Seal Housing

    3 Installing the Air Locker Figure 9. c Cover the bearing seat area with a rag to protect the inside of the clamshell from metal filings. c Drill through the housing square to the outside surface using an 11.2mm [7/16”] drill. c Tap the hole from the outside using a ¼”...
  • Page 20 3 Installing the Air Locker c Make sure the seal housing tube and the grooves of the seal housing are clean and free from any contaminants (e.g., water, dirt, metal filings, etc.). c Inspect the seal housing O-rings (supplied) for dirt, damage or other conditions which might cause leaks.

  • Page 21: Installing The Bulkhead Fitting

    3 Installing the Air Locker Installing the Bulkhead Fitting c To obtain an oil tight seal, apply a thread sealant to the threads of the bulkhead body. c Slide the bulkhead body over the seal housing tube and screw it into the bulkhead port, and tighten.

  • Page 22: Final Assembly

    3 Installing the Air Locker NOTE : Excessive tightening 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. Final Assembly 3.11 c Turn the shallow half of the clamshell upside down and insert the Air Locker into the seal housing by gently lowering it through the bearing cup and into the seal housing with a gentle twisting motion.

  • Page 23: Checking The Backlash

    3 Installing the Air Locker Checking the Backlash 3.12 c Refer to your vehicle manufacturer’s service manual for the specified maximum and minimum amounts of backlash. If the backlash measured here is not within the specifications then the differential will have to be re-shimmed. c Set a long series lever type dial indicator on one of the ring gear teeth.
  • Page 24 3 Installing the Air Locker Re-Shimming the Backlash 3.12.1 NOTE : This step is only necessary when adjusting for incorrect backlash. c Remove the bolts from the clamshell housing. c With the shallow half of the clamshell sitting firmly on a horizontal surface, lift off the deep half of the clamshell.

  • Page 25: Bench Testing The Air Locker

    NOTE : An accurate way to test for air leaks is to fit a shut-off valve to an air pressure gauge. (ARB part # ALTG01 shown in Fig.14.). Once 620 KPA [90 PSI] is reached close the valve, disconnect the air hose, and watch to see if there is any drop in pressure.

  • Page 26: Reinstalling The Differential Assembly

    3 Installing the Air Locker Reinstalling the Differential Assembly 3.14 c Reassemble the differential assembly according to your vehicle manufacturer’s service manual using gasket sealant where necessary. NOTE : Be careful not to damage the sintered bushings in the ends of the Air Locker when installing axle stubs. The fit should be snug, and light tapping may be required to fully insert the stubs into the splines.

  • Page 27: Installing The Air System

    4 Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 4.1.1 (Fig.15.) c Remove one of the 1/8” BSP plugs from its port in the compressor tank. c Apply Teflon paste to the nipple (1/8” X 1/8” BSP) and insert it into the port and tighten.
  • Page 28 For ease of installation, quality of air supply, and a high level of dependability from your Air Locker(s), ARB strongly recommends use of a genuine ARB Air Compressor, however, the Air Locker air system can be operated on any alternate air source that meets each of the following guidelines: c Must supply a minimum of 85PSI [586kPa].

  • Page 29: Running & Securing The Air Line

    4 Installing the Air System Running and Securing the Air Line The path taken by the air line from your air source (i.e., compressor) to your Air Locker is unique to your vehicle and the position of your air source. Plan ahead carefully when running the air line and always follow these guidelines: c Account for axle travel when running the line from the axle to a fixed point on the vehicle.

  • Page 30: Connection To The Bulkhead Fitting

    4 Installing the Air System Connection to the Bulkhead Fitting c Trim the air line to length using a sharp knife. c Insert the support spring over the end of the air line - small end first. (Fig.17.) c Insert the outer compression nut over the air line. Figure 16.

  • Page 31: Mounting & Connecting The Electrical System

    Switch(es) should not be mounted where they will be exposed to water (e.g., in the lower section of an inner door panel). c ARB recommends that you apply the Air Locker warning sticker (ARB part # 210101) within close visual proximity of the switch location.

  • Page 32: Wiring The Actuator System

    Connection to an ARB Air Compressor 5.2.1 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 : RDCKA & RDCKA24 model looms shown for reference only.
  • Page 33 5 Mounting & Connecting the Electrical System SWITCH TERMINAL IDENTIFICATION Figure 20. Connection to an Alternate Air Source 5.2.2 When connecting the actuation switch to an alternate air source, the switch(es) should be wired according to Figures 21. and 22., depending on whether one or two Air Lockers will be installed in the vehicle.
  • Page 34 5 Mounting & Connecting the Electrical System Dual Air Locker System 5.2.2.2 c If two Air Lockers are to be installed in the system, ARB recommends that the switches and solenoids be wired according to Figure 22. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.

  • Page 35: Testing & Final Assembly

    6 Testing & Final Assembly Leak Testing c With the vehicle parked and the engine off, turn the compressor on and wait until the air system is fully charged. NOTE : With the Air Locker(s) disengaged, the air source (i.e., compressor) should not have to recharge over time.

  • Page 36: Re-Sealing & Filling The Differential

    The wheels should again rotate in opposite directions. 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.

  • Page 37: Post-Installation Check List

    6 Testing & Final Assembly Post-Installation Check List Now that the Air Locker installation has been completed, ARB recommends that you take the time to complete the following check list just to insure that you haven’t missed any of the vital steps.
  • Page 38 6 Testing & Final Assembly...

  • Page 39: Parts List

    7 Parts List Exploded Assembly Diagram (see itemized parts list overleaf) Figure 23.

  • Page 40: Itemized Parts List

    7 Parts List Itemized Parts List (see exploded diagram Fig. 23.) RD121 AIR LOCKER MODEL No. : ITEM # DESCRIPTION PART # BONDED SEAL 160702 CLUTCH GEAR 050806 RETURN SPRING 150113 LONG CROSS SHAFT 060204 SPIDER BLOCK 070201 DIFFERENTIAL CASE...

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