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Summary of Contents for ARB Airlocker RD143
- Page 1 RD143 DANA 44, 32 SPLINE, 3.73 & DOWN 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 Removing the Axles & Third Member 2.4 Marking the Bearing Caps 2.5 Checking the Current Backlash Amount 2.6 Removing the Differential Center 2.7 Use of the Thrust Block 3 Installing the Air Locker... -
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, for your differential cover. 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
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
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 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).
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Page 10: Removing The Differential Center
2 Removing the Existing Differential Removing the Differential Center 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: Use Of The Thrust Block
2 Removing the Existing Differential Once the housing has been adequately spread, the differential may be removed by pulling forward on the differential center. NOTE : Keep the bearings and shims separated so that they can be identified as to which end of the differential they came from. -
Page 12: Installing The Air Locker
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 to prevent seizing. Using a bearing press or arbor press, press one of the bearing cones (supplied with the Air Locker kit) onto one bearing journal of the Air Locker (refer to Figure 4.) until the bearing seats firmly against the bearing journal shoulder. -
Page 13: Approximate Backlash Shimming
3 Installing the Air Locker 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 14 (shown as ‘A’ in Fig.5.) and record this measurement as ‘A’. Assemble the new bearing cup and ARB master shim (supplied with your Air Locker kit) onto the right-hand side of the Air Locker (as shown in Fig.
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Page 15: Calculation & Selection Of Shims
Select shims from the shim kit supplied with your Air Locker to make the thickness ‘B’ as determined above. Place this shim pack between the ARB master shim and the bearing cup. Re-measure the new distance ‘C’ from the Air Locker (now including the shim pack ‘B’) to make sure that it matches ‘A’... -
Page 16: Mounting The Ring Gear
3 Installing the Air Locker Mounting the Ring Gear IMPORTANT: Dana 44 ring gears may use either 3/8”, 7/16”, or 1/2” bolts. For 7/16” bolts re-drill Air Locker flange to 11.5mm [29/64”]. For 1/2” bolts re-drill Air Locker flange to 13.0mm [33/64”]. ... -
Page 17: Drilling & Tapping The Bulkhead Port
3 Installing the Air Locker Drilling & 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 18: Modifying The Bearing Cap
3 Installing the Air Locker Modifying the Bearing Cap A 6mm [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 19: Assembling The Seal Housing
Assemble a bearing cup onto the left-hand side of the Air Locker. Assemble one of the two ARB master shims (included with the Air Locker shim kit) onto the stepped face of the seal housing with the rounded edge of the shim facing out. -
Page 20: Pre-Load Shimming
Figure 10. Insert and hold the Air Locker into the differential housing. Insert the remaining ARB master shim from the Air Locker shim kit between the right-hand bearing cup and the bearing seat of the axle housing with the rounded edge of the ARB master shim facing away from the center. - Page 21 NEVER machine the Air Locker. Remove the Air Locker from the axle housing. Install the shim pack ‘D’ between the ARB master shim and the seal housing as shown in Figure 9. Spread the differential housing again (Refer to Section 2.6).
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Page 22: Final Air Locker Assembly
NOTE : The seal housing tube may need to be bent across into the notch of the ARB master shim in order to align it with the drilled hole. DO NOT FORCE THE BEARING CAP ON IF THE TUBE IS NOT YET ALIGNED CORRECTLY WITH THE HOLE. -
Page 23: Final Backlash Checking
3 Installing the Air Locker Final Backlash Checking 3.10 Set a depth indicator on one of the ring gear teeth as in Figure 12. 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 24: Setting Up The Bulkhead Fitting
3 Installing the Air Locker Setting Up the Bulkhead Fitting 3.11 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 25: Profiling The Seal Housing Tube
3 Installing the Air Locker Profiling the Seal Housing Tube 3.12 Completely remove the differential spreader. Without using sharp, jagged tools such as pliers (usually your hands are the best tool for this job), gently bend the seal housing tube so that it runs closely around the top half of the ring gear and then straight out through the bulkhead fitting port without the sides of the tube coming into contact with the ring gear. -
Page 26: 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 27: Reinstalling The Differential & Axles
3 Installing the Air Locker Reinstalling the Differential & Axles 3.14 Reinstall the third member to the differential housing according to your vehicle service manual. NOTE : Thrust block should now be inserted into the Air Locker IF REQUIRED. Use of the thrust block on vehicles which DO NOT require a thrust block may result in damage to the hubs when the axle bolts are tightened up. -
Page 28: Installing The Air System
Installing the Air System Mounting the Solenoid Connection to an ARB Air 4.1.1 Compressor (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 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 In the case of an IFS axle assembly or in the case that the axle assembly has been completely removed from the vehicle, the assembly will have to be remounted in order to position the bulkhead fitting in its correct location for air line access. -
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 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.19.) NOTE : 180409 model loom shown for reference only. Refer to your ARB Air Compressor Installation Guide for details on configuring your installation. - Page 34 5 Mounting & Connecting the Electrical System Figure 19.
- Page 35 5 Mounting & Connecting the Electrical System SWITCH TERMINAL IDENTIFICATION Figure 20. 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 21. and 22., depending on whether one or two Air Lockers will be installed in the vehicle.
- Page 36 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 22. 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: Testing The Air Locker Actuation
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 Parts List...
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Page 41: Parts List
Parts List RD143 Dana 44,32 SPL,3.73 & DN Exploded Assembly Diagram (See itemized parts list overleaf) Figure 23. 7.2 Specifications 32 tooth, Ø35.8mm [1.41”] Axle Spline Ratio Supported 3.73:1 & down 141.3mm [5.56”] Ring Gear ID 216mm [8.5”] Ring Gear OD 10 bolts on Ø168mm [6.61”] Ring Gear Bolts 3/8”... -
Page 42: Itemized Parts List
Suitable for use with ABS tone ring. 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. 2102143 Revision 27/10/2020 Copyright © 2016 by ARB Corporation Limited...
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