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Summary of Contents for ARB RD269
- Page 1 RD269 DODGE RAM 1500 31SPL 9.25” REAR ZF C-CLIP AXLE AIR OPERATED LOCKING DIFFERENTIAL INSTALLATION GUIDE...
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Page 2: Arb 4X4 Accessories
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 of 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 Mounting the Ring Gear 3.2 Assembling the Seal Housing... -
Page 4: 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 5: Tool-Kit Recommendations
A lubricant drain reservoir. 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 soft hammer (e.g. raw hide of nylon) ... -
Page 6: 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 7: Removing Of 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 8: Marking The Bearing Caps
2 Removing the Existing Differential Marking the Bearing Caps Using a small pointed center punch, gently mark the bearing caps in a way that will enable you to know which cap is ‘LEFT’ and which cap is ‘RIGHT’, which way is ‘UP’ and which way is ‘DOWN’. (Fig.1.) HINT : Many installers choose to make one punch mark on... -
Page 9: 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 10 2 Removing the Existing Differential While supporting the pinion gear by holding the pinion 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). This value is referred to as the ring and pinion backlash.
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Page 11: Removing The Differential Carrier
2 Removing the Existing Differential Removing the differential carrier Remove both adjuster nut locking tabs. Unbolt and remove both bearing caps. Using the supplied hex tool on an extension bar, loosen both adjuster nuts at least half a turn. ... -
Page 12: Installing The Air Locker
3 Installing the Air Locker Mounting the Ring Gear Remove the bolts that hold the ring gear in place. Using a plastic or copper hammer, tap in a circle around the ring gear to separate it from the differential carrier. ... - Page 13 3 Installing the Air Locker Figure 4.
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Page 14: Assembling The Seal Housing
3 Installing the Air Locker Assembling the Seal Housing Figure 5. 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 15: Installing The Carrier Bearings
3 Installing the Air Locker NOTE : A twisting motion (i.e., a slight rotation while pressing the seal housing on) will allow the O-rings to engage gently and prevent them from twisting. Twisted O-rings will result in pre-mature O-ring wear and oil contamination in the air system due to the helical shape formed by the O-ring mould line. -
Page 16: Drilling And Tapping The Bulkhead Port
3 Installing the Air Locker Invert the Air Locker and press the flange side bearing cone onto the flange side bearing journal of the differential carrier until the bearing seats firmly against the bearing journal shoulder. Drilling and Tapping the Bulkhead Port An airline port must be drilled and tapped through the differential housing to mount the bulkhead fitting into. -
Page 17: Final Air Locker Assembly
3 Installing the Air Locker Final Air Locker Assembly Using the provided hex tool on an extension bar, loosen both adjuster nuts so that they are as far into the axle tube as they will go to give extra room for the Air Locker. ... -
Page 18: Checking The Backlash
3 Installing the Air Locker Checking the Backlash Set a depth indicator on one of the ring gear teeth. (Fig.8.) Figure 8. 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 19: Setting Up The Bulkhead Fitting
3 Installing the Air Locker Tighten all bearing caps bolts with a torque wrench to the torque specified in your vehicle manufacturer’s service manual. Reinstall the adjuster nut locking tabs. Setting up the Bulkhead Fitting Apply thread sealant to the outside threads of the bulkhead body. ... - Page 20 3 Installing the Air Locker Insert the free end of the seal housing tube into the bulkhead fitting until it protrudes approximately 8mm [5/16”] through the other side. From the outside of the housing, assemble one of the small O-rings over the top of the short length of seal housing tube protruding through the bulkhead fitting.
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Page 21: Profiling The Seal Housing Tube
3 Installing the Air Locker Profiling the Seal Housing Tube With the seal housing tube now firmly secured into the bulkhead fitting, bend the tube so that it closely follows the profile shown in Fig.11. Check that the contour of the tube will not interfere with the axle housing, the bearing caps, the Air Locker, the ring gear or the differential cover. -
Page 22: 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 23: Reinstalling Differential And Axles
3 Installing the Air Locker Reinstalling Differential and Axles 3.10 Unscrew and remove the long cross shaft retaining pin using a 5mm hex key (Fig.13.). NOTE : The long cross shaft retaining pin is the pin located exactly one quarter turn of the differential from the ‘C’ clip access window. - Page 24 3 Installing the Air Locker Using needle nosed pliers or your fingers, insert one of the ‘C’ clips onto the groove in the axle shaft by sliding it between the spider block and a side gear. (Refer to Fig.15.) NOTE : You may have to slide the axle shaft outward very slightly to adequately line up the groove.
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Page 25: Installing The Air System
4 Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor ( 4.1.1 Fig.16. 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
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 28: Connection To The Bulkhead Fitting
4 Installing the Air System NOTE : To remove the air line from the push-in fitting; push the air line as far into the fitting as possible and hold, push inward on the flange, and then pull the air line free of the fitting. - Page 29 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.
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Page 30: 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 31: 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.19.) NOTE : 180409 model loom shown for reference only. Refer to your ARB Air Compressor Installation Guide for details on configuring your installation. -
Page 32: Single Air Locker System
5 Mounting & Connecting the Electrical System SWITCH TERMINAL IDENTIFICATION Figure 20. 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 Fig.21. and Fig.22. depending on whether one or two Air Lockers will be installed in the vehicle. -
Page 33: Dual Air Locker System
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 Fig.22. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on. -
Page 34: Testing & Final Assembly
6 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. -
Page 35: 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 36: Post-Installation Check List
6 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
7 Parts List DODGE RAM 1500, 31 SPL 9.25” Rear ZF C-clip RD269 Exploded Assembly Diagram (See itemized parts list overleaf) Figure 23. Specifications Axle Spline 31 tooth, Ø33.7mm [1.33”] Ratio Supported 144.5mm [5.69”] Ring Gear ID Ring Gear OD 234.86mm [9.25”]... -
Page 38: Itemized Parts List
For replacement O-rings use only BS142 Viton 75. Available only as complete 5 gear set # 728K191C Available only as complete thrust washer kit #730K01 2 brackets are supplied to suit different bearing cap profile Part No. 2102269 Revision 14/06/2024 Copyright © 2020 by ARB Corporation Limited...
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