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Summary of Contents for ARB Airlocker RD158
- Page 1 RD158 DANA 50, 30 SPLINE AIR OPERATED LOCKING DIFFERENTIAL INSTALLATION GUIDE...
- Page 2 No liability is assumed for damages resulting in the use of the information contained herein. ARB Air Locker Air Operated 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.
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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 Disconnecting the Axles 2.4 Marking the Bearing Caps 2.5 Checking the Current Backlash Amount 2.6 Removing the Differential Center 3 Bench Measurement 3.1 Measurement of Pre-Load 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
An automotive brake tubing cutter to cut the copper tube. A razor knife to cut the nylon tubing. A differential housing spreader (e.g. ARB Spreader #0770003, if applicable), to facilitate removal of the carrier. (not required on aluminum housings) ... -
Page 7: Removing The Existing Differential
2 Removing the Existing Differential Vehicle Support 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: Disconnecting The Axles
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 Locker. -
Page 9: 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 after market ring and pinion sets have been manufactured to run with different backlash settings than those specified by your vehicle manufacturer. -
Page 10: Removing The Differential Center
2 Removing the Existing Differential Removing the Differential Center IMPORTANT: SPREAD THE HOUSING FOR REMOVAL AND INSTALLATION OF DIFFERENTIALS (IF APPLICABLE) Spreading the differential housing with a differential case spreader is a step which is critical to set up bearing pre-load on cast iron differential housings (See Figure 3.). -
Page 11: Bench Measurement
3 Bench Measurement Measurement of Pre-Load Shimming In order to reproduce a similar 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. Figure 4. - Page 12 3 Bench Measurement AIR LOCKER DIFFERENTIAL Figure 6. 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 Fig. 5.) and record this measurement as ‘A’.
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Page 13: Calculation & Selection Of Shims
3 Bench Measurement Calculation & Selection of Shims Ideally, the measurement you recorded as ‘A’ from the OE differential will closely match ‘C’ on the Air Locker differential (within 0.1mm [0.004”]). However, quite often these measurements will vary slightly between one factory differential and the next. If this is the case you must create a new shim pack thickness by using the measurements you recorded earlier to find a desired measurement for ‘D’... -
Page 14: Installing The Air Locker
4 Installing the Air Locker Installing the Carrier Bearings With the Air Locker well supported in an arbor press, apply a thin film of high pressure grease to both bearing journals. Identify the bearings according to where each was removed from the OE diff, and allocate them to the correct sides of the Air Locker respectively. -
Page 15: Mounting The Ring Gear
4 Installing the Air Locker Mounting the Ring Gear Apply a thin film of high-pressure grease to the ring 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, and the mating surfaces of the ring gear and the Air Locker flange. -
Page 16: Drilling And Tapping The Bulkhead Port
4 Installing the Air Locker Drilling and Tapping the Bulkhead Port A port must be drilled and tapped through the differential housing to allow the seal housing tube through the housing to connect with the air line from the air compressor. ... -
Page 17: Assembling The Differential Carrier
(e.g. water, dirt, metal fillings etc.) Place the bearing cup over the bearing cone, then ARB master shim over the cup (Figure 9.). Generously lubricate the O-rings with oil prior to assembly, then insert them into the grooves of the seal housing. -
Page 18: Calculation & Selection Of Pre-Load Shims
4 Installing the Air Locker Calculation & Selection of Pre-Load Shims In order to pre-load the tapered roller bearings in your Air Locker, measurements need to be taken so that a value can be calculated for the shim thickness ‘E’ in Figure 9. ... -
Page 19: Reinstalling The Bearing Caps
4 Installing the Air Locker Reinstalling the Bearing Caps IMPORTANT: The ARB master shim must be assembled between the stepped side of the seal housing and the bearing cup. NOT HAVING THE ARB MASTER SHIM IN PLACE HERE WILL CAUSE BEARING FAILURE. -
Page 20: Checking The Backlash
4 Installing the Air Locker Checking the Backlash Set a depth indicator on one of the ring gear teeth as in Figure 11. While supporting the pinion gear by holding the drive shaft, rotate the differential in both directions while observing the maximum variation in depth from the indicator (i.e., the highest value minus the lowest value). -
Page 21: Profiling The Seal Housing Tube
4 Installing the Air Locker To increase the amount of backlash, increase the shim thickness ‘D’ (Fig.6.) and decrease the shim thickness ‘E’ (Fig. 6.) by the same amount. Reverse this step to decrease the backlash. Remount the differential as before. ... -
Page 22: Setting Up The Bulkhead Fitting
4 Installing the Air Locker Setting Up the Bulkhead Fitting NOTE : Use an automotive brake line tubing cutter to cut the seal housing tube. Never use a hacksaw for trimming the steel tube as this will leave metal fillings in the air system. -
Page 23: Leak 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 # 0770005). 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 24: Reinstalling The Axles
4 Installing the Air Locker NOTE : Do not spray this soapy mixture inside the differential. Check that leaky fittings have been adequately tightened. Disassemble, clean threads, and reapply thread sealant if leaking persists. If a leak is found at the seal housing, carefully remove the seal housing assembly and examine the O-rings. -
Page 25: Installing The Air System
Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 5.1.1 (Fig.15.) Remove one of the 1/8” BSP plugs from its port in the compressor tank. Apply Teflon paste to the nipple (1/8” X 1/8” BSP) and insert it into the port and tighten. - Page 26 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: ...
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Page 27: Running & Securing The Air Line
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: ... -
Page 28: Connection To The Bulkhead Fitting
Installing the Air System Connection to the Bulkhead Fitting 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. 16.) Insert the outer compression nut over the air line. ... -
Page 29: 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). ARB recommends that you apply the Air Locker Warning Sticker (ARB part # 210101) within close visual proximity of the switch location. -
Page 30: Wiring The Actuator System
Connection to an ARB Air Compressor 6.2.1 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. 18.) NOTE : 180409 model loom shown for reference only. Refer to your ARB Air Compressor Installation Guide for details on configuring your installation. - Page 31 6 Mounting & Connecting the Electrical System Figure 18. SWITCH TERMINAL IDENTIFICATION Figure 19.
- Page 32 6 Mounting & Connecting the Electrical System Connection to an Alternate Air Source 6.2.2 When connecting the actuation switch to an alternate air source, the switch(es) should be wired according to figures 20. and 21., depending on whether one or two Air Lockers will be installed in the vehicle. Single Air Locker System 6.2.2.1 ...
- Page 33 6 Mounting & Connecting the Electrical System Dual Air Locker System 6.2.2.2 If two Air Lockers are to be installed in the system, ARB recommends that the switches and solenoids be wired according to figure 21. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.
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Page 34: Testing & Final Assembly
Testing & Final Assembly Leak Testing 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. Intermittent recharging without Air Locker use usually indicates a leak at the solenoid fittings or at the compressor tank O-ring seal. -
Page 35: 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. Install the differential cover using gasket sealant or a new standard differential gasket for your make of vehicle. -
Page 36: Post-Installation Check List
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 37: Parts List
Parts List Exploded Assembly Diagram (See itemized parts list overleaf) Figure 22. -
Page 38: Itemized Parts List
CABLE TIE 180301 WARNING LABEL 210101 BUMPER STICKER 210102 OPERATING & SERVICE MANUAL 210200 INSTALLATION GUIDE 2102158 Not illustrated in exploded view. Available only as complete 6 gear set Part No. 2102158 Revision 7/10/2013 Copyright © 2013 by ARB Corporation Limited...
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