Related Manuals for ARB Airlocker RD205
Summary of Contents for ARB Airlocker RD205
- Page 1 RD205 SUZUKI, 22 SPLINE, 10 BOLT RG 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 & Differential 2.4 Marking the Bearing Caps 2.5 Checking the Current Backlash Amount 2.6 Removing the Differential Carrier 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 pliers. (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 from the third member. Remove the adjuster nuts. Carefully remove the differential carrier from the third member. ... -
Page 11: 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 12: Installing The Carrier Bearings
3 Installing the Air Locker Figure 4. Installing the Carrier Bearings Apply a thin film of high pressure grease to the bearing journals of the Air Locker, then press the bearing cones onto the bearing journals as shown in Figure 5. Figure 5. -
Page 13: 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 right hand side (opposite the ring gear) toward the top of the differential housing that is in an area well clear of the differential, the ring gear, and any other obstructions that could snag the seal housing tube. -
Page 14: Final Air Locker Assembly
3 Installing the Air Locker Tap the hole from the outside using ¼”NPT thread tap. 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. -
Page 15: Checking The Backlash
3 Installing the Air Locker Checking the Backlash Set a depth indicator on one of the ring gear teeth (Fig.8.). 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). -
Page 16: Installing The Seal Housing
3 Installing the Air Locker Installing the Seal Housing Make sure the grooves and airway of the seal housing are clean and free from any contaminants (e.g. water, dirt, metal filings, etc.). Inspect the seal housing O-rings (supplied) for dirt, damage or other conditions which might cause leaks. -
Page 17: Setting Up The Bulkhead Fitting
3 Installing the Air Locker Install the spring clip by first hooking both ends of the clip into the small aligned cutouts of the seal housing and the adjuster nut, and then snapping the clip into the groove of the seal housing using a screwdriver. - Page 18 3 Installing the Air Locker IMPORTANT: The seal housing must still be able to freely float after the tube is connected to the bulkhead fitting. Therefore, it is critical to ensure that the tube is not under any tension. To avoid this always leave the tube long enough so that a hook shape can be formed between the seal housing and the bulkhead.
- Page 19 3 Installing the Air Locker Figure 12. NOTE : Make sure the seal housing tube is all of the way into the center compression nut while you are tightening NOTE : Firmly tighten the center compression nut so that a good seal is formed around the tube.
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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 of the differential. (Figs.13., 14. & 15.) ... - Page 21 3 Installing the Air Locker Figure 15. IMPORTANT: In order for the seal housing to float and self center on the bearing journal, the seal housing tube must not be pulling against the seal housing. To check this, rotate the drive flange back and forth while observing the seal housing movement.
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Page 22: 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 # 0770005 shown in Fig.16.). 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 23: Reinstalling The Differential & Axles
3 Installing the Air Locker Reinstalling Differential and Axles 3.10 Replace the paper gasket on the axle housing flange. Reinstall the third member to the differential housing according to your vehicle service manual. Reinstall the drive shaft. ... -
Page 24: Installing The Air System
4 Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 4.1.1 (Fig.17.) 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 25 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 26: 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 27: Connection To The Bulkhead Fitting
4 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 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.20.) 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 21. 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 22. and 23. 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 23. 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 RD205 Suzuki,FR,22 SPL,10 bolt RG Exploded Assembly Diagram (See itemized parts list overleaf) Figure 24. Specifications Axle Spline 22 tooth, Ø23.9mm [0.94”] Ratio Supported All Ring Gear ID 108.0mm [4.25”] Ring Gear Bolts 10 bolts on Ø130mm [5.12”] Ring Gear Torque 95Nm [70 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 seal housing set-up refer to tech note (Section 5.2). For 26 spline model refer to RD208 (Section 2.208) Part No. 2102205 Revision 27/10/2020 Copyright © 2015 by ARB Corporation Limited...
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