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Related Manuals for ARB AIRLOCKER RD180
Summary of Contents for ARB AIRLOCKER RD180
- Page 1 RD180 NISSAN R180A, 27 SPLINE, 3.69 & 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 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: 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 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 (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 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 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 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 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 3 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 3 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 ‘D’ in Fig. 5. Use the following calculation: A + B – C = D (Replacement Shim Pack) HINT : If your calculations are correct then the following...
- Page 13 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 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 4 Installing the Air Locker Assembling the Seal Housing Figure 7. 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 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 ‘E’ in Figure 7. ...
- Page 17 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 8.
- Page 18 4 Installing the Air Locker Modifying the Bearing Cap Clearance for the seal housing tube must be made in the bearing cap. Marking the Tube Position 4.6.1 Without using a spreader, fill the gap (end float) between the master shim and the housing with a required thickness of shims. ...
- Page 19 4 Installing the Air Locker Measure to the bearing cap from exactly the same position on the differential housing that you took the previous measurements from. (Fig. 10.) Mark the tube position where the clearance is to be made for the seal housing tube with a center punch.
- Page 20 4 Installing the Air Locker Drilling the Bearing Cap 4.6.2 Hold the bearing cap steady for drilling in a soft jawed vise clamp. NOTE : Do not apply too much clamping pressure with the vise. The bearing cap may be damaged. ...
- Page 21 4 Installing the Air Locker Final Backlash Checking 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 22 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 caps. Remove the differential. To increase the amount of backlash, reduce the shim thickness ‘E’ (Fig.
- Page 23 4 Installing the Air Locker Figure 15. 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.
- Page 24 4 Installing the Air Locker Reinstall the differential cover onto the differential housing by firstly inserting the free end of the seal housing tube through the bulkhead port from the inside. No gasket sealant or gasket is required at this time.
- Page 25 4 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 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 27 4 Installing the Air Locker Reinstalling the Differential and Axles 4.11 Remove the center compression nut. Remove the differential cover plate and apply gasket sealant (or a gasket) on the edges all round, then reinstall it onto the housing. NOTE : Carefully tip the cover plate upside down and shake the two o-rings and spacer out from within the...
- Page 28 Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 5.1.1 (Fig.19.) 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 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 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 32 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 33 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. 22.) NOTE : 180409 model loom shown for reference only. Refer to your ARB Air Compressor Installation Guide for details on configuring your installation.
- Page 34 6 Mounting & Connecting the Electrical System Figure 22. SWITCH TERMINAL IDENTIFICATION Figure 23.
- Page 35 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 24. and 25., depending on whether one or two Air Lockers will be installed in the vehicle. Single Air Locker System 6.2.2.1 ...
- Page 36 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 25. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.
- Page 37 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 38 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 39 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 RD180 Nissan R180A,27 SPL,3.69 & UP Exploded Assembly Diagram (See itemized parts list overleaf Figure 26. Specifications Axle Spline 27 tooth, Ø27.8mm [1.09”] Ratio Supported 3.69 & Up Ring Gear ID 115.0mm [4.53”] Ring Gear Bolts 10 bolts on Ø142mm [5.59”] Ring Gear Bolts Size 12mm Ring Gear Torque...
- Page 42 Available only as complete thrust washer kit #730J01 All diffs produced before serial #17070001 came with 5mm air connection system. For information contact ARB. For ratios of 3.54:1 and down, refer to RD181 (Section 2.181) Part No. 2102180 Revision 27/10/2020 Copyright © 2015 by ARB Corporation Limited...
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