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Summary of Contents for ARB RD166
- Page 1 RD166 DANA 60HD, 35 SPLINE, 4.56 & UP 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 Installing the Air Locker 3.1 Insuring Adequate Oil Drainage 3.2 Approximate Backlash Shimming... -
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
(See Section 3.2) 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 bearing press or arbor press. -
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: YOU MUST SPREAD THE HOUSING Spreading the differential housing with a differential case spreader is a step which is critical to set up bearing pre-load (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 11 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 12: 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 13: 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 14 Remove the bearings from the original carrier using an automotive bearing puller (ARB #0770001). Inspect the bearings for wear or damage and replace if necessary. Apply a thin film of high pressure grease to both bearing journals of the Air Locker to prevent seizing.
- Page 15 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’ will be determined and added later. Figure 7.
- Page 16 3 Installing the Air Locker Select shims from the shim kit supplied with your Air Locker to make the thickness ‘B’ as determined above. NOTE : If necessary, shim kit ‘B’ can be made from the standard Dana shims (not supplied) and put between the bearing cone and bearing seat.
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Page 17: 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 18: 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 19: 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 20: 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 21 Do not spread the housing more than 0.50mm [0.020”]. NOTE : Use the ARB Shim Driver #0770004 to install the supplied Air Locker shims. Rotate the seal housing until the tube is pointing straight out of the axle housing.
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Page 22: Reinstalling The Bearing Caps
3 Installing the Air Locker Reinstalling the Bearing Caps 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. ... -
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 Remount the differential as before. Release spreader tension (if applicable). Check backlash again as before. Setting Up the Bulkhead Fitting Apply thread sealant to the threads of the bulkhead body. Screw the bulkhead body into the tapped hole, and tighten. ... - Page 25 3 Installing the Air Locker Figure 13. 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 14. -
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 (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 28: Installing The Air System
Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 4.1.1 (Fig.16.) 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 29 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 30: 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 31: 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 32 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 33: 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 34: 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.Error! Reference source not found.) NOTE : 180409 model loom shown for reference only. - Page 35 5 Mounting & Connecting the Electrical System Figure 19. SWITCH TERMINAL IDENTIFICATION Figure 20.
- Page 36 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 21. and 22., depending on whether one or two Air Lockers will be installed in the vehicle. Single Air Locker System 5.2.2.1 ...
- 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 22. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.
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Page 38: 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 39: Testing The Air Locker Actuation
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. Replace the differential cover using gasket sealant or a new standard differential cover gasket for your make of vehicle. -
Page 40: 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 41: Parts List
Parts List Exploded Assembly Diagram (See itemized parts list overleaf) Figure 23. -
Page 42: Itemized Parts List
180301 WARNING LABEL 210101 BUMPER STICKER 210102 OPERATION & SERVICE MANUAL 210200 INSTALLATION GUIDE 2102166 Not illustrated in exploded view. ** Available only as complete 6 gear set Part No. 2102166 Revision 7/10/2013 Copyright © 2013 by ARB Corporation Limited...
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