Related Manuals for ARB RD246
Summary of Contents for ARB RD246
- Page 1 RD246 DANA M210/M220, JEEP JL RUBICON, 35 SPL 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 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 1.3 Assembly Type Identification 2 Removing the Existing Differential 2.1 Vehicle Support 2.2 Differential Fluid Drain 2.3 Removing the Axles 2.4 Marking the Bearing Caps 2.5 Checking the Current Backlash Amount 2.6 Removing the Differential Carrier 3 Installing the Air Locker 3.1 Drilling and Tapping the Bulkhead Port... -
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 lubricant drain reservoir. A 11.2mm [7/16”] drill and ¼”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) ... -
Page 7: Assembly Type Identification
Assembly Type Identification IMPORTANT : The RD246 Air Locker is designed for installation in Jeep JL and JT models equipped with the M220 LSD (limited slip differential) rear axle assembly or the M210 open front axle assembly (JT only). It does not suit OEM factory axle shafts and will require custom, aftermarket 35 spline axle shafts. -
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: Removing 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... -
Page 10: Marking The Bearing Caps
2 Removing the Existing Differential Marking the Bearing Caps Using a small pointed center punch, gently mark the bearing caps in a way that will enable you to know which cap is ‘LEFT’ 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... -
Page 11: 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 12: Removing The Differential Carrier
2 Removing the Existing Differential While supporting the pinion gear by holding the pinion flange, 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). This value is referred to as the ring and pinion backlash. - Page 13 2 Removing the Existing Differential 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: Installing The Air Locker
3 Installing the Air Locker Drilling and Tapping the Bulkhead Port An air line port must be drilled and tapped through 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. -
Page 15: Approximate Backlash Shimming
3 Installing the Air Locker Figure 5. Drill an 11.2mm [7/16”] diameter hole through the differential housing square to the outside surface. Tap the hole from the outside using ¼”NPT thread tap. Remove any sharp edges that may chip off from around the hole and fall into the housing. - Page 16 3 Installing the Air Locker Examine the bearing cups and cones from Figure 7. for damage or wear. If necessary, discard and replace with the same size and type of bearing. FACTORY DIFFERENTIAL Figure 7. 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’...
- Page 17 3 Installing the Air Locker AIR LOCKER DIFFERENTIAL RING GEAR FLANGE 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’.
-
Page 18: 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 19: Assembling The Seal Housing
3 Installing the Air Locker Assembling the Seal Housing Figure 6. 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 20: Installing The Carrier Bearings
3 Installing the Air Locker Installing the Carrier Bearings Apply a thin film of high pressure grease to the bearing journals of the Air Locker, then press the bearing cones onto the bearing journals as shown in Figure 9. Figure 9. - Page 21 3 Installing the Air Locker 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 tapped holes with compressed air (if wet). ...
-
Page 22: 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 11. Figure 11. - Page 23 3 Installing the Air Locker Figure 12. Add the specified preload amount to the end float measurement determined with the feeler gauge to determine a shim amount for ‘E’ (Refer to Figure 11.). PRELOAD + END FLOAT = SHIM PACK ...
-
Page 24: Setting Up The Bulkhead Fitting
3 Installing the Air Locker Setting up the Bulkhead Fitting Apply thread sealant to the outside threads of the bulkhead body. Screw the bulkhead body into the tapped hole, and lightly tighten using a 14mm [9/16”] spanner. Wipe the area clean of any excess thread sealant (inside and outside of the housing). - Page 25 3 Installing the Air Locker 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 one of the small O-rings over the top of the short length of seal housing tube protruding through the bulkhead fitting.
-
Page 26: Profiling The Seal Housing Tube
3 Installing the Air Locker Profiling the 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. -
Page 27: 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 (Available as ARB part #0770005). Charge with shop air 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. -
Page 28: Reinstalling Differential And Axles
3 Installing the Air Locker Reinstalling Differential and Axles 3.11 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. -
Page 29: Installing The Air System
4 Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor (Fig. 17.) 4.1.1 Remove one of the 1/8” BSP plugs from its port in the compressor tank. Apply Teflon paste to the 1/8” BSP nipple on the solenoid and insert it into the port and tighten. - Page 30 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: ...
-
Page 31: 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: ... -
Page 32: Connection To The Bulkhead Fitting
4 Installing the Air System NOTE : To remove the air line from the push-in fitting; push the air line as far into the fitting as possible and hold, push inward on the flange, and then pull the air line free of the fitting. - Page 33 4 Installing the Air System Push the airline into the compression fitting body and screw the outer nut down onto it. Using a 12mm spanner, tighten the outer nut onto the compression fitting body. NOTE : Some force is required to crush the ferrule, however the outer compression nut will tighten against a stop.
-
Page 34: 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 35: 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. 20.) NOTE : 180409 model loom shown for reference only. Refer to your ARB Air Compressor Installation Guide for details on configuring your installation. - Page 36 5 Mounting & Connecting the Electrical System SWITCH TERMINAL IDENTIFICATION Figure 21. 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 22. and 23. depending on whether one or two Air Lockers will be installed in the vehicle.
- Page 37 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 23. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.
-
Page 38: Testing & Final Assembly
6 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. -
Page 39: Filling The Differential
Rotate the same wheel. The wheels should again rotate in opposite directions. 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. -
Page 40: 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 41: Parts List
7 Parts List RD246 Dana M210/M220, Jeep JL Rubicon, 35 SPL Exploded Assembly Diagram (See itemized parts list overleaf) Figure 24. Specifications Axle Spline 35 tooth, Ø38.1mm [1.50”] Ratio Supported Ring Gear ID 134.66mm [5.302”] Ring Gear OD Front - 210.00mm [8.267”] Rear - 220.00mm [8.661”]... -
Page 42: Itemized Parts List
For replacement O-rings use only BS148 Viton 75. Available only as complete 6 gear set # 728H031 Available only as complete thrust washer kit #730H01 35 spline axle shafts MUST be used. Part No. 2102246 Revision 31/01/2019 Copyright © 2018 by ARB Corporation Limited...
Need help?
Do you have a question about the RD246 and is the answer not in the manual?
Questions and answers