Related Manuals for Airlocker RD155
Summary of Contents for Airlocker RD155
- Page 1 RD155 MITSUBISHI 9.5”, 33 SPLINE, IRS 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 Marking the Bearing Caps 2.5 Checking the Current Backlash Amount 2.6 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: Marking The Bearing Caps
2 Removing the Existing Differential Marking the Bearing Caps Remove the inspection cover. 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.1.) Figure 1. - Page 9 2 Removing the Existing Differential Set a depth indicator on one of the ring gear teeth as in Figure 2. Figure 2. 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 10: 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 11: 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 12 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.4.) 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 ‘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 14: Installing The Air Locker
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 one of the bearing journals of the Air Locker until the bearing seats firmly against the bearing journal shoulder. -
Page 15: Assembling The Seal Housing
Installing the Air Locker NOTE : Avoid using the bolts to pull down the ring gear as this puts excess strain on the bolts and the differential flange. Apply a thread locking compound to the thread of each ring gear bolt before inserting it. -
Page 16: Calculation & Selection Of Pre-Load Shims
Installing the Air Locker Generously lubricate the O-rings with oil prior to assembly, then insert them into the grooves of the seal housing. NOTE : When assembling the O-rings, be careful not to leave them twisted when seated in the grooves as this could cause excessive wear and leakage. - Page 17 Installing the Air Locker Consult your vehicle manufacturer’s service manual to determine the carrier bearing pre-load amount specified for your vehicle. NOTE : If your service manual specifies preload in terms of a torque value measured off the drive pinion flange, then assume a preload amount of 0.25mm [0.01”] for the following calculations.
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Page 18: Drilling And Tapping The Bulkhead Port
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. Mark a spot on the exterior of the differential housing toward the top in an area that will be well clear of the Air Locker body, the ring gear, and any other obstructions that could snag the seal housing tube. -
Page 19: Final Air Locker Assembly
Installing the Air Locker Final Air Locker Assembly Spread the differential housing again (Refer to section 2.6). Hold shim packs ‘D’ (Refer to section 3.2) and ‘E’ (Refer to section 4.4) in position on the Air Locker ensuring to line up the seal housing tube with the slot in shim pack ‘E’. -
Page 20: Profiling The Seal Housing Tube
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 4.7.1 NOTE : This step is only necessary when adjusting for... - Page 21 Installing the Air Locker Figure 11. Figure 12.
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Page 22: Setting Up The Bulkhead Fitting
Installing the Air Locker Figure 13. 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. Wipe the area clean of any excess thread sealant (inside and outside of the housing). - Page 23 Installing the Air Locker Figure 14. 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 24: Bench Testing The Air Locker
Installing the Air Locker Bench Testing the Air Locker 4.10 To test the Air Locker; when 620kPa [90 PSI] shop air is applied to the seal housing tube, the Air Locker should engage. Check all fittings and the seal housing for air leaks. ... -
Page 25: Reinstalling The Differential And Axles
Installing the Air Locker Reinstalling the Differential and Axles 4.11 Using an appropriate sealant or gasket, reinstall the cover plate. Reinstall the differential housing to the vehicle according to your vehicle service manual. Insert both axles fully into the housing, engaging the splines, and then gently tap them inwards. -
Page 26: Installing The Air System
Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 5.1.1 (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 27 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 28: 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 29: 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.17.) Insert the outer compression nut over the air line. ... -
Page 30: Mounting & Connecting The Electrical System
6 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 31: Wiring The Actuator System
6 Mounting & Connecting the Electrical System 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. - Page 32 6 Mounting & Connecting the Electrical System SWITCH TERMINAL IDENTIFICATION Figure 20. 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 21. and 22., depending on whether one or two Air Lockers will be installed in the vehicle.
- 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 22. 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: 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 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 23. -
Page 38: Itemized Parts List
Parts List Itemized Parts List (See exploded diagram Figure 23.) RD155 AIR LOCKER MODEL No. : ITEM # DESCRIPTION PART # SEAL HOUSING ASSEMBLY 081813 TAPERED ROLLER BEARING NOT SUPPLIED FLANGE CAP ASSEMBLY 027324 BONDED SEAL 160702 CLUTCH GEAR 050806...
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