Related Manuals for Airlocker RD110
Summary of Contents for Airlocker RD110
- Page 1 RD110 MITSUBISHI IFS, 28 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. 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 Marking the Bearing Caps 2.5 Checking the Current Backlash Amount 2.6 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: 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 Secure the differential assembly to a workbench. Completely remove the front access cover. Using a small 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’... -
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 Remove the floating shaft or ADD (Automatic Differential Disconnect) unit (if present) from the side of the differential housing. Remove the bearing cap retaining bolts and then remove both bearing caps. -
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 IMPORTANT: As the Hyundai Terracan has Ø12mm ring gear bolts, fitment to this vehicle will require drilling the flange holes of the Air Locker from Ø10.2mm to Ø12.2mm [31/64”] to suit. ... -
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 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 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 Figure 7. Add the specified preload amount to the end float measurement determined with the feeler gauge to determine a shim amount for ‘E’ (Refer to Figure 6.). PRELOAD + END FLOAT = SHIM PACK ...
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Page 18: 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 19: 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, screw it into the bulkhead port (from the outside), and tighten. Wipe the area clean of any excess thread sealant (inside and outside of the housing). -
Page 20: Installing The Differential Center
3 Installing the Air Locker Install the seal housing onto the Air Locker by carefully sliding it over the bearing journal by hand with a gentle twisting motion. This will allow the O-rings to engage gently. Rotate the seal housing a few turns to make sure it rotates freely and smoothly. - Page 21 3 Installing the Air Locker Carefully spread the housing (Fig 10.) just enough to install the differential carrier (Refer to your vehicle’s service manual). NOTE : Never spread the housing more than 0.5mm [0.020”]. While holding the bearing cup onto the carrier bearing, hold the shim packs ’D’...
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Page 22: Setting Up The Bulkhead Fitting
3 Installing the Air Locker Setting Up the Bulkhead Fitting 3.10 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 23: 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. ... - Page 24 3 Installing the Air Locker NOTE : Any contact due to vibration or shock could wear the tube over time and eventually cause a leak. Keep the tube away from any sharp edges of the bearing cap or any other part of the differential housing. ...
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Page 25: 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 26: 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 27: 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 bushing in the end of the Air Locker when installing axle stubs. The fit should be snug, and light tapping may be required to fully insert the stub into the spline. - Page 28 3 Installing the Air Locker Figure 17. Approx. Ø18mm [Ø11/16”] hole Install the differential assembly into the vehicle. When inserting the CV axle into the differential housing a gentle tap will be required to seat the retaining clip. NOTE : Be careful not to damage oil seals with the axles.
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Page 29: Installing The Air System
4 Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 4.1.1 (Fig.18.) 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 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 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 33 4 Installing the Air 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 34: 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 35: 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 36 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 37 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 38: 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 39: Re-Sealing & Filling The Differential
6 Testing & Final Assembly 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 40: 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 41: Parts List
7 Parts List RD110 MITSUBISHI IFS,28 SPL Exploded Assembly Diagram (see itemized parts list overleaf) Figure 25. Specifications Axle Spline 28 tooth, Ø28.8mm [1.13”] Ratio Supported Ring Gear ID 124.0mm [4.88”] Ring Gear Bolts 10 bolts on Ø150mm [5.91”] Ring Gear Torque... -
Page 42: Itemized Parts List
7 Parts List Itemized Parts List (see exploded diagram Fig.25. ) ITEM # DESCRIPTION PART # NOTES BONDED SEAL 160701SP CLUTCH GEAR & WAVESPRING KIT 050902SP WAVESPRING 150702SP LONG CROSS SHAFT 061302SP SPIDER BLOCK 070503SP DIFFERENTIAL CASE 013107SP RETAINING PIN SET (PK OF 4) 120601SP TAPERED ROLLER BEARING NOT SUPPLIED...
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