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Summary of Contents for ARB AIRLOCKER RD145
- Page 1 RD145 ROCKWELL 2.5T, 16 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.
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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 Removing the Differential Carrier 3 Installing the Air Locker 3.1 Re-Mounting the Ring Gear 3.2 Assembling the Seal Housing 3.3 Installing the Carrier Bearings... -
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
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: Removing The Axles
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 9: Removing The Differential Carrier
2 Removing the Existing Differential Removing the Differential Carrier Remove both adjuster nut locking tabs. Loosen both bearing caps. Using the appropriate adjuster nut wrench, loosen the adjuster nuts at least half a turn. Remove the bearing caps. ... -
Page 10: Installing The Air Locker
3 Installing the Air Locker Re-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 two halves of the original differential carrier. - Page 11 3 Installing the Air Locker Apply a thin film of high pressure grease to the ring gear diameter of the flange cap and install the flange cap into the ring gear. Apply a thread locking compound to the thread of each ring gear bolt before inserting into the Air Locker.
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Page 12: Assembling The Seal Housing
3 Installing the Air Locker Assembling 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 13: Installing The Carrier Bearings
3 Installing the Air Locker Installing the Carrier Bearings If the tapered roller bearings from the original differential carrier are to be reused, then remove them with an automotive bearing puller and inspect them for damage and/or wear and replace them if necessary. -
Page 14: Drilling And Tapping The Bulkhead Port
3 Installing the Air Locker Drilling and Tapping the Bulkhead Port An airline port must be drilled and tapped through the axle housing casting to mount the bulkhead fitting into. Cover the worm gear area with rags to protect from metal filings. ... -
Page 15: Final Air Locker Assembly
3 Installing the Air Locker Final Air Locker Assembly Reinstall the Air Locker into the axle housing. Install the bearing caps oriented as they were marked before they were removed. Rotate the seal housing so the slot and the tube are pointing straight out of the axle opening. -
Page 16: Profiling The Seal Housing Tube
3 Installing the Air Locker Profiling the Seal Housing Tube Without using sharp, jagged tools such as pliers (your hands are the best tool for this job), gently bend the seal housing tube so that it runs in a loop beside the flange cap and out through the tapped bulkhead port as shown in Figures , and NOTE :... -
Page 17: Setting Up The Bulkhead Fitting
3 Installing the Air Locker Figure 11. Setting Up the Bulkhead Fitting Trim the seal housing tube that is extended through the bulkhead port to approximately 8mm [5/16”] long using an automotive brake line tubing cutter. NOTE : Never use a hacksaw to cut the seal housing tube as this will leave metal filings in the air system. - Page 18 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 19: 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 #ALTG01). 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 20: Installing The Air System
Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 4.1.1 (Fig.14.) Remove one of the 1/8” BSP plugs from its port in the compressor manifold. Apply Teflon paste to the 1/8” BSP nipple on the solenoid and insert it into the port and tighten. - Page 21 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 22: 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 23: Connection To The Bulkhead Fitting
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 24 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 25: 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 26: 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 27 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 28 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 29: 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 30: 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. Refill the differential until level with the filler hole. -
Page 31: 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 32 Testing & Final Assembly...
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Page 33: Parts List
Parts List Exploded Assembly Diagram (See itemized parts list overleaf) Figure 21. Specifications Axle Spline 16 tooth, Ø41.3 [1.625”] Ratio Supported Ring Gear ID 206.38mm [8.125”] Ring Gear OD 268mm [10.55”] Ring Gear Bolts 8 bolts on Ø181.1mm [7.13”]... -
Page 34: Itemized Parts List
Available only as complete thrust washer kit #730K01. All diffs produced before serial #17070001 came with 5mm air connection system. For information contact ARB. For the 40 spline OE shaft model see RD200 (Section 2.200). Part No. 2102145 Revision 27/10/2020 Copyright © 2013 by ARB Corporation Limited...
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