Related Manuals for Airlocker RD219
Summary of Contents for Airlocker RD219
- Page 1 RD219 T6 RANGER/BT50, IFS, 29 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. 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 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: Pre-Installation Preparation
2 Removing the Existing Differential 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
2 Removing the Existing Differential 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: 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: 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 9 2 Removing the Existing Differential Insert a large flat screwdriver or pry-bar through the oil fill hole so that you can stop the differential from rotating (Figure 2.) Figure 2. Gently rotate the pinion gear in both directions and observe the maximum variation in depth from the indicator (i.e., the highest value minus the lowest value).
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Page 10: Removing The Differential Center
2 Removing the Existing Differential Removing the Differential Center Remove all bolts from around the outside of the clamshell. Gently pry the clamshell apart and remove the differential center. Remove the floating shaft (or ADD unit if present) from the side of the differential housing. -
Page 11: 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 12 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 3.) and record this measurement as ‘A’.
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Page 13: 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 14: 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 15: 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 the smaller tapered roller bearing cones onto the bearing journal opposite to the ring gear flange of the differential carrier (as shown in Figure 5.) until the bearing seats firmly against the bearing journal shoulder. -
Page 16: 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 6. Figure 6. - Page 17 3 Installing the Air Locker Assemble the shim pack onto the seal housing flange on the same side as the seal housing tube’s solder joint. Assemble the seal housing into the bearing bore in the shallow half of the clamshell (shims against the clamshell). ...
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Page 18: Calculation & Selection Of Preload Shims
3 Installing the Air Locker Calculation & Selection of Preload Shims Consult your vehicle manufacturer’s service manual to determine the carrier bearing preload 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. - Page 19 3 Installing the Air Locker Figure 8. Figure 9. NOTE : To best determine the correct vertical position of the drilled hole, measure down from the machined face (shown at the top of the picture in Figure 9.) a distance of 18mm [23/32”] and mark the horizontal line which the hole is centered on.
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Page 20: Installing The Seal Housing
3 Installing the Air Locker Figure 10. Cover the bearing seat area with a rag to protect the inside of the clamshell from metal filings. Drill through the housing square to the outside surface using an 11.2mm [7/16”] drill. ... - Page 21 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.
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Page 22: Installing The Bulkhead Fitting
3 Installing the Air Locker Installing the Bulkhead Fitting To obtain an oil tight seal, apply a thread sealant to the threads of the bulkhead body. Slide the bulkhead body over the seal housing tube and screw it into the bulkhead port, and tighten. -
Page 23: Final Assembly
3 Installing the Air Locker Final Assembly 3.11 Turn the shallow half of the clamshell upside down and insert the Air Locker into the seal housing by gently lowering it through the bearing cup and into the seal housing with a gentle twisting motion. This will allow the O-rings to engage gently. -
Page 24: 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. ... - Page 25 3 Installing the Air Locker Figure 15. Gently rotate the pinion gear in both directions and observe 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 26 3 Installing the Air Locker Re-Shimming the Backlash 3.12.1 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.
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Page 27: 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 28: Reinstalling The Differential Assembly
3 Installing the Air Locker Reinstalling the Differential Assembly 3.14 Ensure that any oil seals you removed from the differential housing have been either re-installed or replaced. Reassemble the differential assembly according to your vehicle manufacturer’s service manual using gasket sealant where necessary. -
Page 29: Installing The Air System
4 Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 4.1.1 (Fig.17.) 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 30 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: ...
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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 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.19.) Insert the outer compression nut over the air line. Figure 18. -
Page 33: 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 34: 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.21.). - Page 35 5 Mounting & Connecting the Electrical System SWITCH TERMINAL IDENTIFICATION Figure 22. 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 23. and 24., depending on whether one or two Air Lockers will be installed in the vehicle.
- Page 36 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 24. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.
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Page 37: 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 38: 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 39: 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 40 6 Testing & Final Assembly...
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Page 41: Parts List
7 Parts List Exploded Assembly Diagram (see itemized parts list overleaf) Figure 25. -
Page 42: Itemized Parts List
7 Parts List Itemized Parts List (see exploded diagram Fig. 25.) RD219 AIR LOCKER MODEL No. : ITEM # DESCRIPTION PART # BONDED SEAL 160701 CLUTCH GEAR 050802 PINION THRUST WASHER 150112 PINION GEAR 728J101** LONG CROSS SHAFT 061302 SHORT CROSS SHAFT...
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