ARB AIRLOCKER RD182 Installation Manual
ARB AIRLOCKER RD182 Installation Manual

ARB AIRLOCKER RD182 Installation Manual

Nissan r180a, 27 spline, 8 bolt rg

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RD182
NISSAN R180A, 27 SPLINE,
8 BOLT RG
AIR OPERATED
LOCKING DIFFERENTIAL
INSTALLATION GUIDE

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Summary of Contents for ARB AIRLOCKER RD182

  • Page 1 RD182 NISSAN R180A, 27 SPLINE, 8 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 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 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 Housings 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

    (See Section 3 Bench Measurement)  An 11.2mm [7/16”] drill and ¼” NPT tap for bulkhead fitting installation.  An automotive bearing puller (e.g. ARB Bearing Puller #0770001) or a differential carrier bearing puller.  A bearing press or arbor press.
  • Page 7: Removing The Existing Differential

    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: Marking The Bearing Housings

    Figure 1. 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. Although ARB must...
  • Page 9: Removing The Differential Carrier

    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 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 10: Bench Measurement

    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

    Bench Measurement  Using a caliper or similarly accurate measurement method (i.e., able to take accurate measurements within 0.04mm [0.0015”]), measure the distance from the shoulder of the bearing journal to the ring gear mounting face (shown as ‘A’ in Fig.4.) and record this measurement as ‘A’.
  • Page 12 Bench Measurement If this is the case you must create a new shim pack thickness by using the measurements you recorded earlier to find a desired measurement for ‘C’ in Fig. 5. Use the following calculation: A – B = C (Replacement Shim Pack) HINT : If your calculations are correct then the following...
  • 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.  Identify the bearings according to where each was removed from the OE diff, and allocate them to the correct sides of the Air Locker respectively.
  • Page 14: Mounting The Ring Gear

    4 Installing the Air Locker Mounting the Ring Gear  Apply a thin film of high-pressure grease to the ring gear shoulder of the Air Locker to prevent seizing.  Thoroughly clean any thread locking compound or other foreign matter from the holes of the ring gear, the threads of the ring gear bolts, and the mating surfaces of the ring gear and the Air Locker flange.
  • Page 15: Assembling The Seal Housing

    4 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 16: Calculation & Selection Of Pre-Load Shims

    4 Installing the Air Locker Calculation & Selection of Pre-Load Shims 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 ‘F’ in Figure 7. ...
  • Page 17: Modifying The Bearing Housing

    4 Installing the Air Locker Modifying the Bearing Housing Clearance for the seal housing tube must be made in the bearing housing. Marking the Tube Position 4.5.1  Insert the bearing housing on the ring gear side of the differential housing and tighten the bolts lightly.
  • Page 18 4 Installing the Air Locker Drilling the Bearing Housing 4.5.2  Hold the bearing housing steady for drilling in a soft jawed vise clamp. NOTE : Do not apply too much clamping pressure with the vise. The bearing housing may be damaged. ...
  • Page 19 4 Installing the Air Locker Inserting Seal Housing and Bearing Cups 4.5.3 The seal housing and bearing cups have to be inserted back into the bearing housings before installing the Air Locker.  Clean all parts thoroughly to ensure there are no foreign particles affecting the assembly of seal housing and bearing cup.
  • Page 20: 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.  Bring the differential housing to the location where it will be installed under the engine bay and verify if the approximate spot as shown in Figure 13., will allow the air line to run out with no obstruction.
  • Page 21: Final Backlash Checking

    4 Installing the Air Locker Final Backlash Checking  With only the bearing cones on the Air Locker, insert the assembly into the differential housing by pointing the case side in first.  Holding the Air Locker in position, insert the seal housing side bearing housing carefully through the side bore, ensuring that the seal housing tube does not get damaged during the process.
  • Page 22: 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.  Remove the bearing housings.  Remove the differential.  To increase the amount of backlash, reduce the shim thickness ‘F’ (Fig.
  • Page 23 4 Installing the Air Locker Figure 16.  Assure that the tube adequately clears all moving parts of the differential assembly. Less than 8mm [5/16”] should be considered too little clearance.  Rotate the differential center a few turns to make sure the tube is not contacting the center at any point.
  • Page 24: Setting Up The Bulkhead Fitting

    4 Installing the Air Locker Setting Up the Bulkhead Fitting  Apply thread sealant to the outside threads of the bulkhead body.  Screw the bulkhead body into the tapped hole, and lightly tighten using a 14mm [9/16”] spanner.  Wipe the area clean of any excess thread sealant (inside and outside of the housing).
  • Page 25: 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). 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 26: Reinstalling The Differential And Axles

    4 Installing the Air Locker Reinstalling the Differential and Axles 4.11  Apply gasket sealant (or a gasket) around the edges of the diff cover, then reinstall it onto the housing.  Tighten all cover bolts according to the torque specifications in your vehicle manufacturer’s service manual.
  • Page 27: Installing The Air System

    Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 5.1.1 (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 28 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 29: 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 30: Connection To The Bulkhead Fitting

    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 31: 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 32: 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. 23.) NOTE : 180409 model loom shown for reference only. Refer to your ARB Air Compressor Installation Guide for details on configuring your installation.
  • Page 33 6 Mounting & Connecting the Electrical System Figure 23. SWITCH TERMINAL IDENTIFICATION Figure 24.
  • Page 34 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 25. and 26., depending on whether one or two Air Lockers will be installed in the vehicle. Single Air Locker System 6.2.2.1 ...
  • Page 35 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 26. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.
  • Page 36: 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 37: Filling The Differential

     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 38: 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 39: Parts List

    Parts List RD182 Nissan R180A,27 SPL,8 Bolt RG Exploded Assembly Diagram (See itemized parts list overleaf Figure 27. Specifications Axle Spline 27 tooth, Ø27.8mm [1.09”] Ratio Supported All Ring Gear ID 115.0mm [4.53”] Ring Gear Bolts 8 bolts on Ø135mm [5.31”] Ring Gear Torque 102Nm [75 ft-lb] Backlash...
  • Page 40: Itemized Parts List

    Available only as complete 6 gear set # 728JA32 Available only as complete thrust washer kit #730JA01 All diffs produced before serial #17070001 came with 5mm air connection system. For information contact ARB. Part No. 2102182 Revision 27/10/2020 Copyright © 2015 by ARB Corporation Limited...

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