Airlocker ARB RD90 Installation Manual
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Airlocker ARB RD90 Installation Manual

Toyota 7.5”, ifs
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RD90
TOYOTA 7.5", IFS
AIR OPERATED
LOCKING DIFFERENTIAL
INSTALLATION GUIDE

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Summary of Contents for Airlocker ARB RD90

  • Page 1 RD90 TOYOTA 7.5”, IFS 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...

  • 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 Differential Assembly 2.4 Checking the Current Backlash Amount 2.5 Removing the Differential Center 3 Installing the Air Locker 3.1 Approximate Backlash Shimming 3.2 Calculation &...

  • 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, Allan keys, and drills.

  • Page 7: Assembly Type Identification

    1 Introduction Assembly Type Identification IMPORTANT: Sections 2 and 3 of this installation guide have been written to accommodate two different styles of Toyota IFS differential housings: the front accessed type with bearing caps (Refer to Fig.1.) the ‘clamshell’ type split housing (Refer to Fig.2.) To eliminate confusion, you should identify which figure your vehicle matches with.

  • 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 2 Removing the Existing Differential Marking the Bearing Caps 2.3.1  Secure the differential assembly to a work bench.  Completely remove the front access cover.  Using a small pointed center punch, gently mark the left bearing cap in a way which will enable you to know which cap is ‘LEFT’ and ‘RIGHT’, and which way is ‘UP’...

  • 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 aftermarket ring and pinion sets have been manufactured to run with different backlash settings than those specified by your vehicle manufacturer.
  • Page 11 2 Removing the Existing Differential Backlash for Clamshell Housing 2.4.2  Set a long series lever type dial indicator on one of the ring gear teeth. Access to the ring gear teeth is gained through the oil filler hole. (Refer to Figure 5.) Figure 5.

  • Page 12: Removing The Differential Center

    2 Removing the Existing Differential Removing the Differential Center  Remove the floating shaft (or ADD unit if present) from the side of the differential housing. NOTE : The floating shaft or stub axle is retained by the same type of clip that was used to retain the outer stub axle. A slide hammer may be required for safe removal.

  • Page 13: Installing The Air Locker

    3 Installing the Air Locker Approximate Backlash Shimming In order to reproduce a similar preload and ring and pinion backlash in your Air Locker to that of your existing differential, measurements need to be taken so that a shim thickness can be calculated. ...
  • Page 14 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 bearing journal to the ring gear mounting face (shown as ‘A’ in Figure 6.) and record this measurement as ‘A’.

  • Page 15: 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 16: 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 17: Installing The Carrier Bearings

    3 Installing the Air Locker Installing the Carrier Bearings  Apply a thin film of high pressure grease to both bearing journals of the Air Locker.  Using a bearing press or arbor press, press one of the original tapered roller bearing cones onto the bearing journal opposite to the ring gear flange of the differential carrier (As shown in Figure 8.) until the bearing seats firmly against the bearing journal shoulder.

  • Page 18: 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 9. Figure 9.
  • Page 19 3 Installing the Air Locker Clamshell Housing Preload 3.5.2  Assemble the shim pack determined earlier as ‘D’ (Fig.7.) into the bearing bore of the deep half of the clamshell.  Using a bearing press or arbor press, press one of the original bearing cups into the bottom of the same bearing bore (i.e., until it stops against the shim pack).

  • Page 20: Calculation & Selection Of Preload Shims

    3 Installing the Air Locker NOTE : The preload gap should be the same when measured all the way around the housing. If this is not true, then reposition the shallow clamshell half and re-measure.  Subtract the amount measured at the preload gap from the thickness of the shim pack placed on top of the bearing cup.

  • Page 21: Drilling & Tapping The Bulkhead Port

    3 Installing the Air Locker Drilling & Tapping the Bulkhead Port A port must be drilled and tapped through the differential housing to allow the seal housing tube through the housing to connect with the air line from the air compressor. ...
  • Page 22 3 Installing the Air Locker HINT : Use the location of the oil vent hole to gauge where the position should be. Figure 12. NOTE : The photograph shows the bulkhead body already installed and the seal housing sitting in position where it will be pressed in later on.

  • Page 23: Installing The Bulkhead Fitting

    3 Installing the Air Locker NOTE : The drawing in Figure 13. shows a cross section of the bulkhead body installed into the clamshell. This shows how critical it is to position the bulkhead port on an angle of approximately 25º in the deepest part of the cavity in the clamshell to allow room for the seal housing tube.
  • Page 24 3 Installing the Air Locker  Make sure the seal housing tube and the grooves 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 25 3 Installing the Air Locker Clamshell Housing Installation 3.9.2  Assemble the shim pack ‘E’ (Fig.9.) into the bearing bore of the shallow half of the clamshell.  Position the seal housing in the same bearing bore so that the end of the seal housing tube is in line with the bulkhead port position (Refer to Figure 15.).

  • Page 26: Setting Up The Bulkhead Fitting

    3 Installing the Air Locker Setting Up the Bulkhead Fitting 3.10  Insert the end of the seal housing tube into the bulkhead fitting and hold it to its full depth.  From the outside of the housing, assemble the small O-ring over the top of the small length of seal housing tube that can be seen inside the bulkhead fitting.

  • Page 27: Final Assembly

    3 Installing the Air Locker Final Assembly 3.11 The seal housing tube needs to be carefully bent so that it will stay clear of any moving parts of the differential and not rub against any sharp stationary edges on the bearing cap or the differential housing. Front Access Housing Tube Profile 3.11.1 ...
  • Page 28 3 Installing the Air Locker Figure 18. Clamshell Housing Tube Profile 3.11.2  Press the seal housing tube flat to the back of the housing as shown in Figure 19. Figure 19.  Insert the Air Locker into the seal housing by gently lowering it into the bearing cup with a gentle twisting motion.

  • Page 29: Checking The Backlash

    3 Installing the Air Locker Checking the Backlash 3.12  Refer to your vehicle manufacturer’s service manual for the specified maximum and minimum amounts of backlash. If the backlash measured here is not within the specifications then the differential will have to be re-shimmed. Backlash for Front Access Housing 3.12.1 ...
  • Page 30 3 Installing the Air Locker  To decrease the amount of backlash, reduce the shim thickness ‘D’ (Fig.7.) and increase the shim thickness ‘E’ (Fig.9.) by the same amount. Reverse this step to increase the backlash.  Remount the differential as before. ...
  • Page 31 3 Installing the Air Locker Re-Shimming the Backlash 3.12.4 NOTE : This step is only necessary when adjusting for incorrect backlash.  Remove the bolts from the clamshell housing.  With the shallow half of the clamshell sitting firmly on a horizontal surface, lift off the deep half of the clamshell.

  • Page 32: Bench Testing The Air Locker

    3 Installing the Air Locker Bench Testing the Air Locker 3.13  To bench 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 33: Reinstalling The Differential Assembly

    3 Installing the Air Locker Reinstalling the Differential Assembly 3.14  Reassemble the differential assembly according to your vehicle manufacturer’s service manual using gasket sealant where necessary. NOTE : Be careful not to damage the sintered bushings in the ends of the Air Locker when installing axle stubs. The fit should be snug, and light tapping may be required to fully insert the stubs fully into the splines.

  • Page 34: Installing The Air System

    4 Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 4.1.1 (Fig.23.)  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 35 4 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: ...

  • Page 36: 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 37: Connection To The Bulkhead Fitting

    4 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.25.)  Insert the outer compression nut over the air line. Figure 24.

  • Page 38: 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 39: Wiring The Actuator System

    5 Mounting & Connecting the Electrical System 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.27.).
  • Page 40 5 Mounting & Connecting the Electrical System SWITCH TERMINAL IDENTIFICATION Figure 28. 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 29. and 30., depending on whether one or two Air Lockers will be installed in the vehicle.
  • Page 41 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 30. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.

  • Page 42: 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 43: Re-Sealing & Filling The Differential

    6 Testing & Final Assembly  Turn the Air Locker switch to the ‘ON’ position. The illuminated symbol on the switch cover should light up.  Rotate the same wheel again.  Both wheels should rotate together.  Turn the switch off again. ...

  • Page 44: 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 45: Parts List

    7 Parts List Exploded Assembly Diagram (see itemized parts list overleaf) Figure 31.

  • Page 46: Itemized Parts List

    7 Parts List Itemized Parts List (see exploded diagram Fig.31. ) RD90 AIR LOCKER MODEL No. : ITEM # DESCRIPTION PART # BONDED SEAL 160701 CLUTCH GEAR 050802 RETURN SPRING 150113 LONG CROSS SHAFT 061302 SPIDER BLOCK 070503 DIFFERENTIAL CASE 013101 CROSS SHAFT RETAINING PIN 120601...

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