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Summary of Contents for ARB Airlocker RD232
- Page 1 TOYOTA 8.9” RR, 32 SPL, 12 BOLT RG, SHIM ADJUSTED 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.
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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
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 Bench Measurement) An 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
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... -
Page 8: Marking The Bearing Caps
Figure 1. 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. Although ARB must... - 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
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 15: 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 16: Assembling The Seal Housing
4 Installing the Air Locker Assembling the Seal Housing Figure 7. 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 17: 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 8. ... -
Page 18: Drilling And Tapping The Bulkhead Port
4 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 (Fig.9.). Consider one of the two options recommended for the bulkhead fitting location. ... -
Page 19: Modifying The Bearing Cap
4 Installing the Air Locker Modifying the Bearing Cap A 6.35mm [1/4”] hole must be drilled in the seal housing bearing cap for the seal housing tube to pass through. ~30° Figure 10. NOTE : Take time and double check when drilling, as bearing caps are custom fitted to the axle housing and cannot be replaced. -
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 4.8.1 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 a low profile that hugs the diff housing, running below the Air Locker in order to ensure clearance with the axle case when reinstalled into the axle assembly. ... - Page 23 4 Installing the Air Locker Figure 13. OPTION 1 Figure 14. OPTION 1 ...
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Page 24: Setting Up The Bulkhead Fitting
4 Installing the Air Locker Figure 15. OPTION 2 Check that the contour of the tube will not interfere with the Air Locker or the ring gear. NOTE : It is a good idea to keep the tube away from the bearing caps or any other part of the differential casting as any contact due to vibration or shock may wear the tube and eventually cause a leak. -
Page 25: 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. 16.), and screw it into the bulkhead body, and tighten using Pozidriv #3 screwdriver. -
Page 26: 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 27: Concealing The Oe Diff Lock Wiring
4 Installing the Air Locker Concealing the OE Diff Lock Wiring 4.13 NOTE : This section is only applicable for vehicles originally equipped with an OE diff lock. NOTE : Some wiring work needs to be done to avoid having a warning light appear on the dash, due to the removal of an OE diff lock (Fig. -
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 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
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 33: 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. (Fig.22.) NOTE : 180409 model loom shown for reference only. Refer to your ARB Air Compressor Installation Guide for details on configuring your installation. - Page 34 6 Mounting & Connecting the Electrical System Figure 22. SWITCH TERMINAL IDENTIFICATION Figure 23.
- Page 35 6 Mounting & Connecting the Electrical System 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 24. and 25., depending on whether one or two Air Lockers will be installed in the vehicle.
- Page 36 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 25. 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
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 38: Filling The Differential
Rotate the same wheel. The wheels should again rotate in opposite directions. Filling the Differential NOTE : Consult the ARB Air Locker Operating & Service Manual for recommendations on differential lubricant specifications. Remove the filler plug. Refill the differential until level with the filler hole. -
Page 39: 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 40 Testing & Final Assembly...
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Page 41: Parts List
Parts List RD232 Toyota 8.9” RR, 32 SPL, 12 Bolt RG, Shim Adjusted Exploded Assembly Diagram (See itemized parts list overleaf Figure 26. 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 42: Itemized Parts List
Toyota OEM carrier bearing PN: 90366-T0068 (Flange Cap Side, LHS) 90366-T0071 (Diff Case Side, RHS) All diffs produced before serial #17070001 came with 5mm air connection system. For information contact ARB. Part No. 2102232 Revision 28/06/2017 Copyright © 2015 by ARB Corporation Limited...
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