Related Manuals for Airlocker RD129
Summary of Contents for Airlocker RD129
- Page 1 TOYOTA TACOMA/TUNDRA, REAR, 30 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 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 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. Checking the Current Backlash Amount IMPORTANT: This step is a precautionary measure recommended by ARB due... - 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 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
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 16: 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 17: Drilling And Tapping The Bulkhead Port
4 Installing the Air Locker Select suitable shims from the shim kit supplied with your Air Locker to make up a shim pack of this thickness. (Refer to section 3.2 for methods of shim adjustment). The seal housing will have to be removed in order to add shim pack ‘E’. -
Page 18: Modifying The Bearing Cap
4 Installing the Air Locker Remove any sharp edges that may chip off from around the hole and fall into the housing. Very carefully, remove the rags and inspect with a service light inside the housing to insure no metal filings are left behind. Modifying the Bearing Cap ... -
Page 19: 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 4.4) in position on the Air Locker. ... -
Page 20: Final Backlash Checking
4 Installing the Air Locker Final Backlash Checking Set a depth indicator on one of the ring gear teeth as in Fig. 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 21: Profiling The Seal Housing Tube
4 Installing the Air Locker Profiling the Seal Housing Tube The seal housing tube will need a profile that hugs the Air Locker and the bearing cap in order to ensure clearance with the axle case when reinstalled into the axle assembly. ... - Page 22 4 Installing the Air Locker Wipe the area clean of any excess thread sealant (inside and outside of the housing). Insert the free end of the seal housing tube into the bulkhead fitting until it protrudes approximately 8mm [5/16”] through the other side. ...
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Page 23: Bench Testing The Air Locker
4 Installing the Air Locker Bench Testing the Air Locker 4.11 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 24: Reinstalling The Differential And Axles
4 Installing the Air Locker Reinstalling the Differential and Axles 4.12 Reinstall the third member to the differential housing according to your vehicle service manual. Reinstall the drive shaft. Replace the axle seals if necessary and fit to the axles. ... -
Page 25: Installing The Air System
Mounting & Connecting the Electrical System Mounting the Solenoid Connection to an ARB Air Compressor 5.1.1 (Fig.14.) 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 26 Mounting & Connecting the Electrical 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 27: Running & 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 28: Connection To The Bulkhead Fitting
Mounting & Connecting the Electrical 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 29: 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 30: Wiring The Actuator System
6 Mounting & Connecting the Electrical System Figure 16. 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 31 6 Mounting & Connecting the Electrical System Figure 17. SWITCH TERMINAL IDENTIFICATION Figure 18.
- Page 32 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 19. and 20., 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 20. 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 RD129 Toyota Tacoma,RR Exploded Assembly Diagram (See itemized parts list overleaf Figure 21. Specifications Axle Spline 30 tooth, Ø33.0mm [1.30”] Ratio Supported Ring Gear ID 127.5mm [5.02”] Ring Gear OD 213mm [8.4”] Ring Gear Bolts 12 bolts on Ø152mm [5.98”]... -
Page 38: Itemized Parts List
Parts List Itemized Parts List (See exploded diagram figure 21.) ITEM # DESCRIPTION PART # NOTES SEAL HOUSING O-RINGS (PK OF 2) 160207SP SEAL HOUSING KIT 081807SP SHIM KIT SHK009 MASTER SHIM 150305 BONDED SEAL 160702SP CLUTCH GEAR & WAVESPRING KIT 050906SP SPIDER BLOCK 070201SP...
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