ARB AIRLOCKER RD249CE Installation Manual
  1. Manuals
  2. Brands
  3. ARB Manuals
  4. Automobile Accessories
  5. AIRLOCKER RD249CE
  6. Installation manual
ARB AIRLOCKER RD249CE Installation Manual

ARB AIRLOCKER RD249CE Installation Manual

Ford 10", 40 spline, competition edition
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
RD249CE
FORD 10", 40 SPLINE,
COMPETITION EDITION
AIR OPERATED
LOCKING DIFFERENTIAL
INSTALLATION GUIDE

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the AIRLOCKER RD249CE and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for ARB AIRLOCKER RD249CE

Summary of Contents for ARB AIRLOCKER RD249CE

  • Page 1 RD249CE FORD 10”, 40 SPLINE, COMPETITION EDITION 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 Carrier 3 Installing the Air Locker 3.1 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

     A standard automotive feeler gauge.  A razor knife to cut the nylon tubing.  An adjuster-nut wrench. (e.g., ARB Adjuster Nut Pliers #0770002)  A torque wrench. (See vehicle service manual for required torque range.)  A lubricant drain reservoir.

  • Page 7: Assembly Type Identification

    1 Introduction Assembly Type Identification IMPORTANT: ARB’s RD249CE Air Locker differential was not designed for use with the factory standard Ford third member assembly (i.e., the original third member produced by the Ford Motor Company to accept either 28 or 31 spline axle shafts), or for use with aftermarket 35 spline assemblies.

  • Page 8: Removing The Existing Differential

    IN THE PAST MAY HAVE RESULTED IN SOME DEGREE OF BENDING IN THE AXLE HOUSING. 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...

  • Page 9: Marking The Bearing Caps

    2 Removing the Existing Differential Removing the Third Member  Disconnect the drive shaft from the pinion flange.  Remove both of the rear wheels and brake drums/rotors according to your vehicle manufacturer’s service manual.  Slide the axle shafts outward until they are completely disengaged from the splines of the differential side gears.

  • Page 10: 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 aftermarket ring and pinion sets have been manufactured to run with different backlash settings than those specified by your vehicle manufacturer.

  • Page 11: 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, adjuster nuts, and tapered roller bearing cups.

  • Page 12: Installing The Air Locker

    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 until the bearing seats firmly against the bearing journal shoulder.

  • Page 13: Re-Mounting The Ring Gear

    3 Installing the Air Locker Re-Mounting the Ring Gear IMPORTANT: Due to the harsh applications that this Air Locker is used in, ARB has designed the RD249CE to use the supplied 1/2” diameter ARP ring gear bolts. ARP part # 6AR1.200-1S.
  • Page 14 You must use the supplied locking tabs to secure the ring gear bolts. Ford 10” diffs used in high performance applications often suffer from loose ring gear bolts. To avoid this happening, ARB has designed the RD249CE to utilize the supplied locking tabs.
  • Page 15 3 Installing the Air Locker Modifying the housing The pinion support bearing housing must be ground back to create clearance for the Air Locker (Fig. 7.). Figure 7. GRINDING REQUIRED HERE FOR CLEARANCE  Remove the pinion shaft assembly from the third member. ...
  • Page 16 3 Installing the Air Locker Figure 8. Figure 9.
  • Page 17 3 Installing the Air Locker Drilling the bulkhead port The Gearworks housing comes with a port for the bulkhead fitting pre- drilled near the adjuster nut threads. If using the Gearworks bulkhead location, the tube hole will have to be enlarged to 6.35mm (1/4”) as shown in Figure 10.

  • Page 18: Checking For Assembly Clearance

    3 Installing the Air Locker Checking for Assembly Clearance IMPORTANT: Some third member castings will require modification for correct Air Locker installation. A properly installed Air Locker will have no less than 1mm [1/32”] between any part of the differential carrier and the third member casting. ...
  • Page 19 IMPORTANT: The supplied adjuster nut has been manufactured by ARB to match the thread size on an acquired sample. ARB cannot ensure that after market diff housings are manufactured to the same tolerance. Therefore ARB recommends that installers use Loctite 272 thread lock (or equivalent) on the ARB adjuster nut when installing it.

  • Page 20: Checking The Backlash

    3 Installing the Air Locker Checking the Backlash  Set a depth indicator on one of the ring gear teeth (Fig.12.).  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 21: 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 22 3 Installing the Air Locker  Carefully install the seal housing by sliding it all of the way onto the bearing journal, aligning the keys to the adjuster nut so the tube is pointing straight up, as shown in Figure 15. Figure 15.

  • Page 23: Profiling The Seal Housing Tube

    3 Installing the Air Locker Profiling the Seal Housing Tube 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 loops over the bearing cap, and goes through the bulkhead port hole as shown in Figures 16.

  • Page 24: Setting Up The Bulkhead Fitting

    3 Installing the Air Locker Setting Up the Bulkhead Fitting 3.10  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 25 3 Installing the Air Locker 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 26: 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 27: Reinstalling The Differential And Axles

    3 Installing the Air Locker Reinstalling the Differential and Axles 3.12  Reinstall the third member to the differential housing according to your vehicle service manual.  Reconnect the drive shaft.  Inspect the condition of the axle seals and replace if necessary. ...

  • Page 28: Installing The Air System

    4 Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 4.1.1 (Fig.20.)  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 29 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 30: 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 31: Connection To The Bulkhead Fitting

    4 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 32 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.

  • Page 33: 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 34: 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. 23.) NOTE : 180409 model loom shown for reference only. Refer to your ARB Air Compressor Installation Guide for details on configuring your installation.
  • Page 35 5 Mounting & Connecting the Electrical System Figure 23. SWITCH TERMINAL IDENTIFICATION Figure 24.
  • Page 36 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 25. and 26., depending on whether one or two Air Lockers will be installed in the vehicle. Single Air Locker System 5.2.2.1 ...
  • Page 37 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 26. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.

  • Page 38: 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 39: 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 40: 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 41: Parts List

    Parts List Ford 10”,40 SPL RD249CE Exploded Assembly Diagram (See itemized parts list overleaf) Figure 27. Specifications Axle Spline 40 tooth, Ø43.4mm [1.71”] Ratio Supported 127.0mm [5.00”] Ring Gear ID Ring Gear OD 254mm [10”] 10 bolts on Ø152mm [6.00”] Ring Gear Bolts Ring Gear Torque 135Nm [100 ft-lb]...

  • Page 42: Itemized Parts List

    RD249CE does not suit the OEM third member. Aftermarket third member with carrier bearing ID of 57.15mm [2.250”] and a bearing thickness of 21.00mm [0.827”] must be used. Part No. 2102249CE Revision 6/06/2018 Copyright © 2017 by ARB Corporation Limited...

Table of Contents