ARB Airlocker RD102 Installation Manual
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ARB Airlocker RD102 Installation Manual

Dana 35, 27 spline, 3.54 & up
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RD102
DANA 35, 27 SPLINE,
3.54 & UP
AIR OPERATED
LOCKING DIFFERENTIAL
INSTALLATION GUIDE

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Summary of Contents for ARB Airlocker RD102

  • Page 1 RD102 DANA 35, 27 SPLINE, 3.54 & UP 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.

  • Page 3: Table Of Contents

    Table of Contents: 1 Introduction 1.1 Pre-Installation Preparation 1.2 Tool-Kit Recommendations 1.3 Assembly Type Identification 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 Center 3 Installing the Air Locker 3.1 Insuring Adequate Oil Drainage...

  • 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: Assembly Type Identification

    1 Introduction Assembly Type Identification IMPORTANT: Sections 2 and 6 of this installation guide have been written to accommodate two different Dana 35 applications: The ‘C’ clip retained axle shaft (Refer to Fig.1.) the non-‘C’ clip type axle shaft (Refer to Fig.2.) To eliminate confusion, you should identify which figure your axle matches with.

  • Page 8: 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 9: 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 10: Marking The Bearing Caps

    2 Removing the Existing Differential  Pull the axle free of the axle bearing using a slide hammer.  Gently slide the axle shafts out of the axle tubes until they can be completely removed from the vehicle. NOTE : The oil seals are delicate and can be easily damaged.

  • Page 11: 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 12: Removing The Differential Center

    2 Removing the Existing Differential Removing the Differential Center IMPORTANT: YOU MUST SPREAD THE HOUSING ON DANA 35 MODELS Spreading the differential housing with a differential case spreader is a step which is critical to set up bearing pre-load on cast iron Dana 35 differential housings.

  • Page 13: Insuring Adequate Oil Drainage

    3 Installing the Air Locker Insuring Adequate Oil Drainage IMPORTANT: Some axles were manufactured with poor oil drainage between the axle tubes and the differential housing. This can often result in one of the axle tubes filling up with differential oil while running.

  • Page 14: Installing The Air Locker

    3 Installing the Air Locker Figure 7. Figure 8. NOTE : Cover the differential housing cavity and the axle tube openings with a rag to protect them from metal filings.
  • Page 15 3 Installing the Air Locker  If no drainage slot is present at the upper left-hand side (refer to Fig.6.) of the housing at all, then a slot (not a hole) will have to be created here as clearance for the seal housing tube (Refer to Section 3.8 Reinstalling the Bearing Caps).

  • Page 16: 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 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 10.) until the bearing seats firmly against the bearing journal shoulder.

  • Page 17: 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 18 3 Installing the Air Locker  Assemble the new bearing cup and master shim (supplied with your Air Locker kit) onto the right-hand side of the Air Locker (as shown in Fig.12.) and measure the total distance ‘B’. NOTE : The shim pack ‘C’...

  • Page 19: Mounting The Ring Gear

    3 Installing the Air Locker  Select shims from the shim kit supplied with your Air Locker to make the thickness ‘C’ as determined above.  Place this shim pack between the master shim and the bearing cup.  Re-measure the new distance ‘B’ from the Air Locker (now including the shim pack ‘C’) to make sure that it matches the distance ‘A’...

  • Page 20: 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 differential housing to mount the bulkhead fitting into. NOTE : Higher ratio gearing uses deeper (thicker) ring gears with teeth that extend much further. Make sure the intended hole location is far enough away from the ring gear teeth that the air line will not be at risk of contact with the current or future ring gears.

  • Page 21: Assembling The Seal Housing

    3 Installing the Air Locker Assembling the Seal Housing Figure 14.  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 22: Pre-Load Shimming

    3 Installing the Air Locker Pre-Load Shimming In order to pre-load the tapered roller bearings in your Air Locker, measurements need to be taken so that a value can be calculated for the shim thickness ‘D’ in Figure 14.  Insert and hold the Air Locker into the differential housing. IMPORTANT: Some Dana 35 pinion gears extend so far into the differential cavity that they make contact with the body of the Air Locker.
  • Page 23 3 Installing the Air Locker Figure 15.  Consult your vehicle manufacturer’s service manual to determine the carrier bearing pre-load amount specified for your vehicle. PRE-LOAD + END FLOAT = SHIM PACK  Add the specified pre-load amount to the measurement taken with the feeler gauge to determine a shim amount for ‘D’...
  • Page 24 3 Installing the Air Locker Figure 16. NOTE : If the master shim is too tight to fully install then the spreader tension may need to be increased. Do not spread the housing more than 0.50mm [0.020”].  Release all spreader tension. ...

  • Page 25: Reinstalling The Bearing Caps

    3 Installing the Air Locker Reinstalling the Bearing Caps IMPORTANT: The Air Locker master shim must be assembled between the stepped side of the seal housing and the bearing cup. NOT HAVING THE MASTER SHIM IN PLACE HERE WILL CAUSE BEARING FAILURE. ...

  • Page 26: Checking The Backlash

    3 Installing the Air Locker Checking the Backlash  Set a depth indicator on one of the ring gear teeth as in Figure 18.  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 27: Setting Up The Bulkhead Fitting

    3 Installing the Air Locker Re-Shimming the Backlash 3.9.1 NOTE : This step is only necessary when adjusting for incorrect backlash.  Remove the bearing caps.  Remove the differential as before.  To decrease the amount of backlash, reduce the shim thickness ‘C’ (Fig.12.) and increase the shim thickness ‘D’...
  • Page 28 3 Installing the Air Locker Figure 19. 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.

  • Page 29: Profiling The Seal Housing Tube

    3 Installing the Air Locker Profiling the Seal Housing Tube 3.11  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 along the inside of the differential housing as shown in Figure 20.

  • Page 30: Installing The Air System

    Mounting & Connecting the Electrical System Mounting the Solenoid Connection to an ARB Air Compressor 4.1.1 (Fig.21.)  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 31 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: ...

  • Page 32: 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 33: Connection To The Bulkhead Fitting

    Mounting & Connecting the Electrical 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 34 Mounting & Connecting the Electrical 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.

  • Page 35: 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 36: 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. 24.) NOTE : 180409 model loom shown for reference only. Refer to your ARB Air Compressor Installation Guide for details on configuring your installation.
  • Page 37 5 Mounting & Connecting the Electrical System Figure 24. SWITCH TERMINAL IDENTIFICATION Figure 25.
  • Page 38 5 Mounting & Connecting the Electrical System 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 26. and 27., depending on whether one or two Air Lockers will be installed in the vehicle. Single Air Locker System 5.2.2.1 ...
  • Page 39 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 27. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.

  • Page 40: 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 41 Testing & Final Assembly Figure 28. Reinstalling ‘C’ Clip Retained Shafts 6.2.1  Remove the long cross shaft. Figure 29.  Rotate the differential until the ‘C’ clip access window is in full view.  Insert both axles fully into the housing and gently tap them inward as far as they will go.
  • Page 42 Testing & Final Assembly Figure 30.  Pull outward on the axle shaft to seat the ‘C’ clip into the side gear.  Repeat the ‘C’ clip installation steps on the second axle shaft.  Re-insert the long cross shaft. ...

  • Page 43: Testing The Air Locker Actuation

     The wheels should again rotate in opposite directions. Re-Sealing & Filling the Differential NOTE : Consult the ARB Air Locker Operating & Service Manual for recommendations on differential lubricant specifications.  Replace the differential cover using gasket sealant or a new standard differential cover gasket for your make of vehicle.

  • Page 44: 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 45: Parts List

    Parts List RD102 Dana 35,27 SPL,3.54 & UP Exploded Assembly Diagram (See itemized parts list overleaf) Figure 31. Specifications Axle Spline 27 tooth, Ø29.5mm [1.16”] Ratio Supported 3.54:1 & up Ring Gear ID 120.7mm [4.75”] Ring Gear OD 193mm [7.6”] Ring Gear Bolts 8 bolts on Ø146mm [5.75”] Ring Gear Torque...

  • Page 46: Itemized Parts List

    Some OEM Dana 35 drive pinion gears extend too far into the centre and converge with the differential carrier. Refer to ring and pinion modification note (Section 5.6) for correction. Part No. 2102102 Revision 26/10/2020 Copyright © 2015 by ARB Corporation Limited...

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