Related Manuals for Airlocker RD157
Summary of Contents for Airlocker RD157
- Page 1 RD157 JEEP JK RUBICON, 35 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. ARB 4x4 ACCESSORIES Corporate Head Office 42-44 Garden St...
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Page 3: Table Of Contents
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... -
Page 5: Introduction
1 Introduction IMPORTANT : BEFORE ATTEMPTING TO DISMANTLE YOUR VEHICLE FOR THIS INSTALLATION, PLEASE READ THIS INSTALLATION GUIDE IN ITS ENTIRETY, AS WELL AS ALL APPLICABLE SECTIONS OF YOUR VEHICLE MANUFACTURER’S SERVICE MANUAL. Pre-Installation Preparation This booklet is to be used in conjunction with your vehicle manufacturer’s service manual. -
Page 6: Tool-Kit Recommendations
1 Introduction Tool-Kit Recommendations Below is a list of tools and supplies you may need to complete this installation. Requirements for your vehicle may vary. Please consult your vehicle service manual for additional recommendations. Tools 1.2.1 Standard automotive sizes (metric and/or imperial) of sockets, wrenches, Alan keys, and drills. -
Page 7: Assembly Type Identification
1 Introduction Assembly Type Identification IMPORTANT: The RD157 ARB Air Locker does not directly replace the factory locking differential in the Jeep JK Rubicon. It is a high performance upgrade that requires special purpose 35 spline aftermarket axle shafts (not included). -
Page 8: 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 9: Disconnecting The Axles
2 Removing the Existing Differential Disconnecting the Axles 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. -
Page 10: 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 11: Removing The Differential Center
2 Removing the Existing Differential Removing the Differential Center 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-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. - Page 12 2 Removing the Existing Differential 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.
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Page 13: Installing The Air Locker
3 Installing the Air Locker Insuring Adequate Oil Drainage IMPORTANT: Some Salisbury axles were manufactured with poor oil drainage between the axle tubes and the differential housing. This can often result in one of the axle tubes filling up with differential oil while running. -
Page 14: Approximate Backlash Shimming
3 Installing the Air Locker NOTE : Make sure any grinding dust, filings or drill chips left behind by cutting the drainage slots is completely cleaned out of the housing. Check that the axle air vents are clear and working correctly. Approximate Backlash 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... - Page 15 3 Installing the Air Locker 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 cup to the ring gear mounting face (shown as ‘A’ in Figure 5.) and record this measurement as ‘A’.
- Page 16 3 Installing the Air Locker Assemble the new bearing cup onto the right-hand side of the Air Locker (as shown in Fig. 7.) and measure the total distance ‘C’. NOTE : The shim pack ‘B’ should not be installed at this time. NOTE : The OE master shim should not be included in measurement ‘C’.
- Page 17 3 Installing the Air Locker 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 –...
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Page 18: Mounting The Ring Gear
3 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 between the ring gear and the Air Locker flange. -
Page 19: Drilling And Tapping The Bulkhead Port
3 Installing the Air Locker Drilling and Tapping the Bulkhead Port An airline port must be drilled and tapped through the differential housing to mount the bulkhead fitting into. NOTE : Higher ratio gearing uses deeper (thicker) ring gears with teeth that extend much further. Make sure the intended hole location is far enough away from the ring gear teeth that the air line will not be at risk of contact with the current or future ring gears. -
Page 20: Assembling The Seal Housing
3 Installing the Air Locker Assembling the Seal Housing Figure 9. Make sure the grooves and airway of the seal housing are clean and free from any contaminants (e.g. water, dirt, metal filings, etc.). Inspect the seal housing O-rings (supplied) for dirt, damage or other conditions which might cause leaks. -
Page 21: Pre-Load Shimming
3 Installing the Air Locker Pre-Load Shimming 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 ‘D’ in Figure 9. Insert and hold the Air Locker into the differential housing. ... -
Page 22: Reinstalling The Bearing Caps
3 Installing the Air Locker Remove the Air Locker from the axle housing. Install the shim pack ‘D’ between the left hand OE master shim and the seal housing as shown in Figure 9. Spread the differential housing again (Refer to Section 2.6). ... -
Page 23: Checking The Backlash
3 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 24: Setting Up The Bulkhead Fitting
3 Installing the Air Locker Re-Shimming the Backlash 3.8.1 NOTE : This step is only necessary when adjusting for incorrect backlash. Remove the bearing caps. Remove the differential as before. NOTE : Never spread the housing on the aluminum models. ... - Page 25 3 Installing the Air Locker Figure 12. 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, the seal housing tube, 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...
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Page 26: Profiling The Seal Housing Tube
3 Installing the Air Locker Profiling the Seal Housing Tube 3.10 Completely remove the differential spreader. 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 runs along the inside of the differential housing as shown in Figure 13. -
Page 27: Installing The Air System
Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 4.1.1 (Fig.14.) 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 28 Installing the Air System Connection to an Alternate Air Source 4.1.2 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 29: 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 30: Connection To The Bulkhead Fitting
Installing the Air System To attach the air line to the push-in fitting of the solenoid; insert the line firmly into the fitting, pull outward on the flange of the fitting while holding the line as far into the fitting as possible, and then gently pull outward on the air line to clamp the line in place. - Page 31 Installing the Air System Screw on the outer compression 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.
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Page 32: Mounting & Connecting The Electrical System
5 Mounting & Connecting the Electrical System Mounting the Actuator Switch(es) Air Locker actuator switch(es) can be easily panel mounted inside the vehicle in a 21mm x 36.5mm [0.83” x 1.44”] rectangular cutout. NOTE : Only attach the cover plate to the face of the switch once the switch has been mounted and wired correctly as the cover plates are designed to be difficult to remove. -
Page 33: Wiring The Actuator System
5 Mounting & Connecting the Electrical System Figure 16. 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. - Page 34 5 Mounting & Connecting the Electrical System Figure 17. SWITCH TERMINAL IDENTIFICATION Figure 18.
- Page 35 5 Mounting & Connecting the Electrical System 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 19. and 20., depending on whether one or two Air Lockers will be installed in the vehicle. Single Air Locker System 5.2.2.1 ...
- Page 36 5 Mounting & Connecting the Electrical System Dual Air Locker System 5.2.2.2 If two Air Lockers are to be installed in the system, ARB recommends that the switches and solenoids be wired according to figure 20. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.
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Page 37: 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 38: Testing The Air Locker Actuation
Testing & Final Assembly Testing the Air Locker Actuation To test that your air system, electrical system, and your Air Locker differential is functioning correctly: Support the vehicle such that the wheels are free to rotate (e.g., on axle stands, a chassis hoist, etc.) ... -
Page 39: 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 40 Testing & Final Assembly...
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Page 41: Parts List
Parts List Exploded Assembly Diagram (See itemized parts list overleaf) Figure 21. -
Page 42: Itemized Parts List
Parts List Itemized Parts List (See exploded diagram figure 21.) RD157 AIR LOCKER MODEL No. : ITEM # DESCRIPTION PART # SEAL HOUSING O-RING 160207 SEAL HOUSING ASSEMBLY 081809 SHIM KIT SHK009 MASTER SHIM 150352 BONDED SEAL 160702 CLUTCH GEAR...
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