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Summary of Contents for ARB Airlocker RD146
- Page 1 RD146 TOYOTA 10.5”, REAR, 36 SPLINE 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 Air Operated 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 Disconnecting the Axles 2.4 Marking the Bearing Caps 2.5 Checking the Current Backlash Amount 2.6 Removing the Differential Center 3 Bench Measurement 3.1 Approximate Backlash Shimming 3.2 Calculation &... -
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 3.2) 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 installing your Air Locker. -
Page 8: Marking The Bearing Caps
2 Removing the Existing Differential Marking the Bearing Caps Using a pointed center punch, gently mark the bearing caps in a way that will enable you to know which cap is ‘LEFT’ and which cap is ‘RIGHT’, which way is ‘UP’ and which way is ‘DOWN’. (Fig.1.) HINT : Many installers choose to make one punch mark on the left hand side of the left hand bearing cap and one... -
Page 9: 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 10: Removing The Differential Center
2 Removing the Existing Differential Removing the Differential Center IMPORTANT: YOU MUST SPREAD THE HOUSING Spreading the differential housing with a differential case spreader is a step which is critical to set up bearing pre-load (See Figure 3.). 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 2 Removing the Existing Differential NOTE : The differential center is heavy and quite difficult to handle when covered in oil. Take care not to drop it. Relieve any tension on the spreader immediately after the differential has been removed.
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Page 12: 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 13 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 14: 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 15: 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 one of the bearing journals of the Air Locker until the bearing seats firmly against the bearing journal shoulder. -
Page 16: Assembling The Seal Housing
4 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 17: Calculation & Selection Of Pre-Load Shims
4 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 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. 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: 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. Figure 8. 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 packs ‘D’ (Refer to section 3.2) and ‘E’ (Refer to section 4.3) in position on the Air Locker. ... -
Page 21: Final Backlash Checking
4 Installing the Air Locker Final Backlash Checking Set a depth indicator on one of the ring gear teeth as in Figure 10. While supporting the pinion gear by holding the drive flange, 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). -
Page 22: Profiling The Seal Housing Tube
4 Installing the Air Locker Profiling the Seal Housing Tube 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 housing and protrudes through the bulkhead port in the differential housing (refer to Fig. -
Page 23: Setting Up The Bulkhead Fitting
4 Installing the Air Locker Figure 12. Setting up the Bulkhead Fitting 4.10 Apply thread sealant to the outside threads of the bulkhead body. Screw the bulkhead body into the tapped hole, and lightly tighten using a 14mm [9/16”] spanner. ... -
Page 24: Bench Testing The Air Locker
4 Installing the Air Locker Figure 13. NOTE : Make sure the seal housing tube is all of the way into the center compression nut while you are tightening NOTE : Firmly tighten the center compression nut so that a good seal is formed around the tube. - Page 25 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.
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Page 26: Installing The Air System
Mounting & Connecting the Electrical System Mounting the Solenoid Connection to an ARB Air Compressor 5.1.1 (Fig.15.) 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 27 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 And Securing The Air Line
Mounting & Connecting the Electrical 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. -
Page 29: Connecting To The Bulkhead Fitting
Mounting & Connecting the Electrical System To attach the air line to the push-in fitting of the solenoid; insert the line firmly into the fitting, pull outward on the flange of the fitting while holding the line as far into the fitting as possible, and then gently pull outward on the air line to clamp the line in place. - Page 30 Mounting & Connecting the Electrical System Push the airline into the compression fitting body and screw the outer nut down onto it. Using a 12mm spanner, tighten the outer nut onto the compression fitting body. NOTE : Some force is required to crush the ferrule, however the outer compression nut will tighten against a stop.
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Page 31: 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 32: 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.18.) NOTE : 180409 model loom shown for reference only. Refer to your ARB Air Compressor Installation Guide for details on configuring your installation. - Page 33 6 Mounting & Connecting the Electrical System Figure 18. SWITCH TERMINAL IDENTIFICATION Figure 19.
- Page 34 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 20. and 21., depending on whether one or two Air Lockers will be installed in the vehicle. Single Air Locker System 6.2.2.1 ...
- Page 35 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 21. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.
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Page 36: 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 37: Testing The Air Locker Actuation
The wheels should again rotate in opposite directions. Re-Sealing & Filling the Differential NOTE : Consult the ARB Air Locker Operating & Service Manual for recommendations on differential lubricant specifications. Replace the differential cover using gasket sealant or a new standard differential cover gasket for your make of vehicle. -
Page 38: 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 39: Parts List
Parts List Toyota 10.5”,RR,36 SPL RD146 Exploded Assembly Diagram (See itemized parts list overleaf) Figure 22. Specifications 36 tooth, Ø36.8mm [1.44”] Axle Spline Ratio Supported 167.0mm [6.57”] Ring Gear ID 267mm [10.5”] Ring Gear OD 12 bolts on Ø204mm [8.03”] Ring Gear Bolts Backlash 0.15-0.25mm [0.006-0.010”]... -
Page 40: Itemized Parts List
(If spring type is changed, a matching diff case must also be used. See item 19.) All diffs produced before serial #17070001 came with 5mm air connection system. For information contact ARB. For the 34 spline model see RD183 (Section 2.183). Part No. 2102146 Revision 27/10/2020 Copyright © 2015 by ARB Corporation Limited...
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