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Summary of Contents for ARB Airlocker RD137
- Page 1 RD137 NISSAN PATHFINDER R51, 33 SPLINE, REAR 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
Either a replacement gasket, or gasket sealant. A sufficient volume of differential oil to completely refill your housing. (see the ARB Air Locker Operating and Service Manual for recommended lubricants) A soap and water mixture to test for air leaks. -
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
Figure 1. Checking the Current Backlash Amount IMPORTANT: This step is a precautionary measure recommended by ARB due to the fact that some after market 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 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 Add the specified pre-load amount to the measurement taken with the feeler gauge to determine a shim amount for ‘E’ in Figure 6. PRE-LOAD + END FLOAT = SHIM PACK Select suitable shims from the shim kit supplied with your Air Locker to make up a shim pack of this thickness. -
Page 18: Modifying The Bearing Cap
4 Installing the Air Locker Remove the Air Locker from the differential housing. Cover the drive pinion area with a rag to protect it from metal filings. Secure the differential housing to the work bench. Drill a 11.2mm [7/16”] diameter hole through the differential housing square to the outside surface. -
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: Profiling The Seal Housing Tube
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 :... - Page 21 4 Installing the Air Locker Figure 12. Figure 13. Run the seal housing tube between the bearing cap, the differential housing, and the cover plate and out of the bulkhead port. Check that the contour of the tube will not interfere with the Air Locker, the ring gear, the master shim, the bearing cap, or the cover plate.
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Page 22: Setting Up The Bulkhead Fitting
4 Installing the Air Locker 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 23: Bench Testing 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 # ALTG01). 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 24: Reinstalling The Differential And Axles
4 Installing the Air Locker Check that leaky fittings have been adequately tightened. NOTE : Do not overtighten fittings. Disassemble, clean threads, and reapply thread sealant if leaking persists. If a leak is found at the seal housing, carefully remove the seal housing assembly and examine the O-rings. -
Page 25: Installing The Air System
Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 5.1.1 (Fig.16.) 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 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
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 28: 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 29: 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 30: Wiring The Actuator System
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. 19.) NOTE : 180409 model loom shown for reference only. Refer to your ARB Air Compressor Installation Guide for details on configuring your installation. - Page 31 6 Mounting & Connecting the Electrical System SWITCH TERMINAL IDENTIFICATION Figure 20. 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 21. and 22., depending on whether one or two Air Lockers will be installed in the vehicle.
- Page 32 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 22. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.
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Page 33: 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 34: 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 35: 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 36 Testing & Final Assembly...
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Page 37: Parts List
Parts List RD137 Nissan Pathfinder R51,33 SPL,RR Exploded Assembly Diagram (See itemized parts list overleaf Figure 23. Specifications 33 tooth, Ø33.3mm [1.31”] Axle Spline Ratio Supported Not 3.36:1 (unconfirmed) 146.0mm [5.75”] Ring Gear ID Ring Gear Bolt Size 13mm 12 bolts on Ø176mm [6.93”] Ring Gear Bolts Ring Gear Torque 203Nm [150 ft-lb]... -
Page 38: Itemized Parts List
Refer to pinion modification tech note (Sec. 5.6). Available only as complete thrust washer kit #730H01 All diffs produced before serial #17070001 came with 5mm air connection system. For information contact ARB. Part No. 2102137 Revision 27/10/2020 Copyright © 2015 by ARB Corporation Limited...
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