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Summary of Contents for ARB Airlocker RD210
- Page 1 RD210 MITSUBISHI 8”, REAR, 28 SPL 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 2.4 Marking the Bearing Caps 2.5 Checking the Current Backlash Amount 2.6 Removing the Differential Carrier 2.7 Use of the Thrust Block 3 Installing the Air Locker 3.1 Mounting the Ring Gear... -
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
A dial indicator or other suitable measuring tool for checking ring & pinion backlash. An adjuster-nut wrench (e.g., ARB Adjuster Nut Pliers #0770002) A razor knife suitable for cutting nylon tubing. A torque wrench. (See your vehicle service manual for the required torque range.) -
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... -
Page 8: Marking The Bearing Caps
2 Removing the Existing Differential Marking the Bearing Caps 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’ and which way is ‘DOWN’. (Fig.1.) ... -
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 after market 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 Carrier
2 Removing the Existing Differential Removing the differential carrier Remove the adjuster nut locking tabs. Remove the bearing caps. Loosen the adjuster nuts. Carefully remove the differential carrier from the housing. Remove the tapered roller bearings from the differential carrier with a bearing puller. -
Page 11: Use Of The Thrust Block
2 Removing the Existing Differential Use of the Thrust Block This Air Locker has been designed to replace both drum and disc brake Mitsubishi diffs. As such, a thrust block used to maintain axle end float has been supplied for drum brake equipped models. NOTE : If you are unsure whether you need to use the thrust block, look down the splines of the OE differential to... -
Page 12: Installing The Air Locker
3 Installing the Air Locker Mounting the Ring Gear Remove the bolts that hold the ring gear in place. Using a plastic or copper hammer, tap in a circle around the ring gear to separate it from the differential carrier. ... - Page 13 3 Installing the Air Locker Figure 4.
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Page 14: 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 15: Drilling And Tapping The Bulkhead Port
3 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 top of the differential, in the position shown. (Fig.6.) Figure 6. -
Page 16: Assembling The Seal Housing
3 Installing the Air Locker Assembling the Seal Housing Apply a thin film of high pressure grease to the outside of the tapered roller bearing cup supplied with the Air Locker. Using a bearing press or arbor press, press the bearing cup into the seal housing (narrow edge first) until it stops at the end of the bore. -
Page 17: Final Air Locker Assembly
Final Air Locker Assembly Place the Air Locker into the differential housing. Place the supplied ARB master shim on the ring gear side of the diff so that it is between the bearing and the adjuster nut, then install the bearing caps (Fig 8.). -
Page 18: Setting Up The Bulkhead Fitting
3 Installing the Air Locker NOTE : You should feel no backlash between the ring and pinion gears once the adjuster nut tightens. Reverse the adjuster nut (counterclockwise) ¼ turn. Insert the case side adjuster nut onto the opposite side of the differential and tighten with the appropriate adjuster nut wrench. - Page 19 3 Installing the Air Locker Insert the free end of the seal housing tube into the bulkhead fitting until it protrudes approximately 8mm [5/16”] through the other side. From the outside of the housing, assemble one of the small O-rings over the top of the short length of seal housing tube protruding through the bulkhead fitting.
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Page 20: Profiling The Seal Housing Tube
3 Installing the Air Locker Profiling the Seal Housing Tube With the seal housing tube now firmly secured into the bulkhead fitting, bend the tube so that it closely follows the profile shown in Fig.11. and 12. Check that the contour of the tube will not interfere with the bearing caps, the ring gear or the axle housing. -
Page 21: 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 (Available as ARB part #0770005). Charge with shop air until 620 KPA [90 PSI] is reached, shut the valve off, disconnect the air hose, and watch to see if there is any drop in pressure. -
Page 22: Reinstalling The Differential & Axles
3 Installing the Air Locker Reinstalling Differential and Axles 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 23: Installing The Air System
4 Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor (Fig.14.) 4.1.1 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 24 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 25: 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 26: Connection To The Bulkhead Fitting
4 Installing the Air System NOTE : To remove the air line from the push-in fitting; push the air line as far into the fitting as possible and hold, push inward on the flange, and then pull the air line free of the fitting. - Page 27 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 28: 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 29: 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.17.) NOTE : 180409 model loom shown for reference only. Refer to your ARB Air Compressor Installation Guide for details on configuring your installation. - Page 30 5 Mounting & Connecting the Electrical System SWITCH TERMINAL IDENTIFICATION Figure 18. 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 19. and 20. depending on whether one or two Air Lockers will be installed in the vehicle.
- Page 31 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 20. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.
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Page 32: 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 33: 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. Refill the differential until level with the filler hole. -
Page 34: 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 35: Parts List
7 Parts List MITSUBISHI 8”, 28 SPL, RR RD210 Exploded Assembly Diagram (See itemized parts list overleaf) Figure 21. Specification Axle Spline 28 tooth, Ø30.5mm [1.20”] Ratio Supported All Ring Gear ID 124.0mm [4.88”] Ring Gear Bolts 10 bolts on Ø150mm [5.91”] Ring Gear Torque 85Nm [63 ft-lb] Backlash 0.13-0.18mm [0.005-0.007”]... -
Page 36: Itemized Parts List
All diffs produced before serial #17070001 came with 5mm air connection system. For information contact ARB. For the larger 9” Mitsubishi 28 spline rear differentials with 12 ring gear bolts refer to RD212 (Section 2.212). Part No. 2102210 Revision 27/10/2020 Copyright © 2015 by ARB Corporation Limited...
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