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Summary of Contents for Airlocker RD253
- Page 1 RD253 TOYOTA 9.5” RR, 32 SPL, OE LOCKER REPLACEMENT 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. 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 2 Removing the Existing Differential 2.1 Vehicle Support 2.2 Differential Fluid Drain 2.3 Removing the Axles and Differential 2.4 Removing OE Locker Mechanism 2.5 Marking the Bearing Caps 2.6 Checking the Current Backlash Amount 2.7 Spreading the Differential Housing 3 Bench Measurement 3.1 Approximate Backlash Shimming... -
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, Allen keys, and drills. -
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: Removing Oe Locker Mechanism
2 Removing the Existing Differential Removing the Axles and Differential Remove the axles according to your vehicle’s service manual. NOTE : Toyota OE Diff Lock must be engaged (rotate dashboard switch to lock rear diff, and rotate wheel to ensure diff is locked) before removing short axle shaft. - Page 9 2 Removing the Existing Differential Undo the 3 bolts that hold the limit switch bracket in position. Remove the bracket and switch from the diff. Unbolt the screw that is retaining the engagement fork to the motor shaft (Fig. 2.). Figure 2.
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Page 10: Marking The Bearing Caps
2 Removing the Existing Differential Marking the Bearing Caps Using a pointed center punch, gently mark the differential housing and the bearing caps in a way that will enable you to correctly position the cap during reassembly. (Fig.3.) Figure 3. Checking the Current Backlash Amount IMPORTANT: This step is a precautionary measure recommended by ARB due... - Page 11 2 Removing the Existing Differential Set a depth indicator on one of the ring gear teeth as in Figure 4. Figure 4. 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).
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Page 12: Spreading The Differential Housing
2 Removing the Existing Differential Spreading the Differential Housing IMPORTANT: Spreading the differential housing with a differential case spreader is a step which is critical to set up bearing pre-load when a differential is installed. 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 13: Bench Measurement
3 Bench Measurement 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 need to be taken so that a shim thickness can be calculated. ... - Page 14 3 Bench Measurement 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.6.) and record this measurement as ‘A’.
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Page 15: Calculation & Selection Of Shims
3 Bench Measurement Calculation & Selection of 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 16: 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. Press one of the tapered roller bearing cones onto the ring gear side bearing journal first until the bearing seats firmly against the bearing journal shoulder. -
Page 17: 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 18: Assembling The Seal Housing
4 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 19: 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 10. ... -
Page 20: Final Air Locker Assembly
4 Installing the Air Locker Final Air Locker Assembly Spread the differential housing again (Refer to section 2.6). Hold shim pack ‘E’ (Refer to section 4.4) in position on the Air Locker. Reinstall the Air Locker into the differential housing. ... - Page 21 4 Installing the Air Locker Refer to your vehicle service manual for the specified maximum and minimum amounts of backlash. If the backlash is not within the specifications then the differential will have to be removed and re- shimmed. Re-Shimming the Backlash 4.6.1 NOTE :...
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Page 22: Profiling The Seal Housing Tube
4 Installing the Air Locker Profiling the Seal Housing Tube The seal housing tube will need to be profiled so that it is clear of both the Air Locker as well as the axle housing. Without using sharp, jagged tools such as pliers (usually your hands are the best tool for this job), bend the seal housing tube so that it closely follows the profile of the differential. - Page 23 4 Installing the Air Locker Figure 13. Figure 14.
- Page 24 4 Installing the Air Locker Figure 15. Check that the contour of the tube will not interfere with the Air Locker or the ring gear. Direct the tube to exit through the opening left by the removal of the OE locker limit switch.
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Page 25: Setting Up The Bulkhead Fitting
4 Installing the Air Locker Setting up the Bulkhead Fitting Two blanking plates (supplied) will need to be bolted to the differential housing to block up the holes left by the removal of the OE Diff Lock motor. One plate is used for the bulkhead fitting, the other is used to support the brake line mounting bracket (Fig. -
Page 26: Bench Testing The Air Locker
4 Installing the Air Locker While holding the seal housing tube into the bulkhead fitting, insert the chamfered end of the center compression nut over the extended tube as shown in the assembly diagram (Fig. 17.), and screw it into the bulkhead body, and tighten using Pozidriv #3 screwdriver. -
Page 27: Reinstalling The Differential And Axles
4 Installing 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 5.1.1 (Fig.19.) 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 29 Installing the Air System Connection to an Alternate Air Source 5.1.2 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 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 Connection to the Bulkhead Fitting Trim the air line to length using a sharp knife. Assemble an aluminium washer onto the banjo bolt and insert through the banjo fitting. Assemble second aluminium washer and tighten into bulkhead fitting using a 14mm [9/16”] spanner. -
Page 32: Mounting & Connecting The Electrical System
6 Mounting & Connecting the Electrical System Rear Differential Lock Sensor Replacement The Toyota Rear Diff Lock contains a senor that provides a signal to the Toyota 4WD Control Computer when the Diff Lock is engaged. This signal is required before the Toyota 4WD Control Computer will allow the Front Diff to be locked. -
Page 33: Wiring Modifications
6 Mounting & Connecting the Electrical System Wiring Modifications Standard Install using Toyota Diff Lock Switch 6.2.1 The Toyota Diff Lock switch should be used instead of the ARB switch as it is not only suitable to switch the ARB Air Locker solenoid, but crucially it also provides a signal to the Toyota 4WD Control Computer which then in turn allows the Front Toyota Diff Lock to be activated. - Page 34 6 Mounting & Connecting the Electrical System Unplug the connector and locate the Green/Red striped wire as shown in Figure 24. This wire receives 12V when the Toyota switch is turned to Rear Diff Lock. Figure 24. Green/Red...
- Page 35 6 Mounting & Connecting the Electrical System Expose the Green/Red striped wire back from the plug in the loose section of the Toyota Harness. Cut the quick connect terminal off the end of the Yellow Air Locker switch wire. ...
- Page 36 6 Mounting & Connecting the Electrical System LINX Install using Toyota Diff Lock Switch 6.2.2 This installation will allow both the Rear ARB Air Locker and the Front Toyota Diff Lock to be controlled by both the ARB LINX and the Toyota Diff Lock switch.
- Page 37 6 Mounting & Connecting the Electrical System Using the following wiring diagram (Figure 27.) and instructions, these two wires can be used by LINX to directly control the rear Air Locker and control the Toyota Front Diff Lock via the Toyota 4WD Control Computer.
- Page 38 6 Mounting & Connecting the Electrical System Expose the Green/Red and Green/White striped wires a few centimeters back from the switch plug in the loose section of the Toyota harness. Cut the Green/Red wire. Also cut the quick connect terminal off the end of the Yellow Air Locker switch wire.
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Page 39: 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 40: Filling The Differential
Testing & Final Assembly Rotate one wheel by hand. The wheel should rotate freely and the opposite wheel should be turning in the opposite direction without any resistance or mechanical noise from within the differential. Turn the Air Locker switch to the ‘ON’ position. The illuminated symbol on the switch cover should light up. -
Page 41: 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 42 Testing & Final Assembly...
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Page 43: Parts List
Parts List RD253 Toyota 9.5” RR, 32 SPL, OE Locker Replacement Exploded Assembly Diagram (See itemized parts list overleaf Figure 28. Specifications Axle Spline 32 tooth, Ø34.8mm [1.37”] Ratio Supported Ring Gear ID 140.95mm [5.55”] Ring Gear OD 225mm [8.86”] Ring Gear Bolts 12 bolts on Ø162.5mm [6.40”]... -
Page 44: Itemized Parts List
Parts List Itemized Parts List (See exploded diagram figure 28.) ITEM # DESCRIPTION PART # NOTES FLANGE CAP KIT 027355SP BONDED SEAL 160702SP CLUTCH GEAR & WAVESPRING KIT 050906SP WAVESPRING 150706SP SHORT CROSS SHAFT 060403SP SEE NOTE SIDE GEAR SIDE GEAR THRUST WASHER SEE NOTE DIFFERENTIAL CASE 013055SP...
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