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Summary of Contents for ARB AIRLOCKER RD131
- Page 1 RD131 TOYOTA 8” IFS, 50MM CARRIER BEARING 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 & Differential 2.4 Marking the Bearing Caps 2.5 Checking the Current Backlash Amount 2.6 Removing the Differential Carrier 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
Any misalignment of the axle tube may result in excessive wear and/or failure of your differential and stub shaft. ARB strongly recommends that you have your axle assembly inspected for concentricity and straightness before... -
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: Removing The Differential Carrier
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). -
Page 10: 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 11: Calculation & Selection Of Shims
3 Bench Measurement Measure the thickness of the factory shim removed from the end of the differential carrier (shown as ‘B’ in Fig.3.) and record this measurement as ‘B’. Figure 4. Measure the distance from the Air Locker bearing shoulder to the ring gear mounting face (shown as ‘C’... - Page 12 3 Bench Measurement HINT : If your calculations are correct then the following equation will also be true: A + B – C – D = ZERO Create a shim pack to match the thickness calculated as ‘D’. To achieve the desired shim thickness you can: •...
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Page 13: 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 14: Assembling The Seal Housing
4 Installing the Air Locker Apply a thread locking compound to the thread of each ring gear bolt before inserting it. NOTE : Do not apply threading compound directly into the threaded hole as this could prevent the bolt from reaching its full depth. -
Page 15: Calculation & Selection Of Pre-Load Shims
4 Installing the Air Locker Lubricate the seal housing running surface on the Air Locker carrier with oil. Assemble the bearing cup onto the left-hand side of the Air Locker. NOTE : No shims should be assembled onto the seal housing at this time. -
Page 16: Drilling And Tapping The Bulkhead Port
4 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 exterior of the differential cover plate in the position shown in Figure 6. -
Page 17: Drilling The Diff Housing For Seal Housing Tube
4 Installing the Air Locker Drilling the Diff Housing for Seal Housing Tube A hole must be drilled through a tab inside the diff housing to cable tie the seal housing tube to for support. Mark a spot on the tab as shown in Figure 7. ... -
Page 18: Final Backlash Checking
4 Installing the Air Locker Final Backlash Checking 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. Reinstall the Air Locker into the differential housing, ensuring that the seal housing is positioned so that the tube will clear the bearing cap. -
Page 19: Profiling The Seal Housing Tube
4 Installing the Air Locker Re-Shimming the Backlash 4.7.1 NOTE : This step is only necessary when adjusting for incorrect backlash. Reapply the spreader to the differential housing. Remove the bearing caps. Remove the differential. To increase the amount of backlash, reduce the shim thickness ‘D’ (Fig.4.) and increase the shim thickness ‘E’... - Page 20 4 Installing the Air Locker Figure 11. Install the differential cover plate onto the differential housing using 2 bolts (hand tight only) to hold the cover in place. Rotate the differential center a few turns to make sure the tube is not contacting the center at any point.
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Page 21: Setting Up The Bulkhead Fitting
4 Installing the Air Locker Remove the cover plate. Using an automotive brake line tubing cutter, trim the tube at the position marked. NOTE : Never use a hacksaw for trimming the copper tube as this will leave metal filings in the air system. ... - Page 22 4 Installing the Air Locker Figure 13. 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 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 Reinstalling the Differential and Axles 4.11 Apply gasket sealant (or a gasket) to the differential cover plate and reinstall it onto the housing. Tighten all cover bolts according to the torque specifications in your vehicle manufacturer’s service manual. -
Page 25: Installing The Air System
Mounting & Connecting the Electrical System Mounting the Solenoid Connection to an ARB Air Compressor 5.1.1 (Fig.15.) 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
Mounting & Connecting the Electrical 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. -
Page 28: Connection To The Bulkhead Fitting
Mounting & Connecting the Electrical 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
Connection to an ARB Air Compressor 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.18.) 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 Figure 18. SWITCH TERMINAL IDENTIFICATION Figure 19.
- Page 32 6 Mounting & Connecting the Electrical System 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 20. and 21., depending on whether one or two Air Lockers will be installed in the vehicle.
- Page 33 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 21. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.
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Page 34: 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 35: 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 36: 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 37: Parts List
Parts List RD131 Toyota 8” IFS,50mm BRNG Exploded Assembly Diagram (See itemized parts list overleaf Figure 22. Specifications Axle Spline 30 tooth, Ø33.0mm [1.30’] Ratio Supported Ring Gear ID 126.0mm [4.96”] Ring Gear OD 203mm [8.0”] Ring Gear Bolts 10 bolts on Ø160mm [6.30”] Ring Gear Torque 96Nm [71 ft-lb] Backlash... -
Page 38: Itemized Parts List
For 8” IFS with 58mm carrier bearings & 34 spline shafts refer to RD141 (Section 2.141). For 8” IFS with 53mm carrier bearings refer to RD111 (Section 2.111) or RD121 (Section 2.121). Part No. 2102131 Revision 20/04/2021 Copyright © 2021 by ARB Corporation Limited...
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