ARB Transmission and Drivetrain Installation Instructions

ARB Transmission and Drivetrain Installation Instructions
INSTALLATION GUIDE
RD129
TOYOTA TACOMA/TUNDRA
REAR,30 SPL
Part No. 2102129
Revision Date 22/02/07
Copyright © 2007 by ARB Corporation Limited
1 Introduction
IMPORTANT :
BEFORE ATTEMPTING TO DISMANTLE YOUR VEHICLE FOR THIS
INSTALLATION, PLEASE READ THIS INSTALLATION GUIDE IN ITS
ENTIRETY, AS WELL AS ALL APPLICABLE SECTIONS OF YOUR
VEHICLE MANUFACTURER’S SERVICE MANUAL.
1.1
Pre-Installation Preparation
This booklet is to be used in conjunction with your vehicle
manufacturer’s service manual. ARB endeavors to account for every
possible variation in vehicle model when publishing its installation
guides, and guides are updated regularly as new model information
becomes available, however, the rapid and globally varied release of
some vehicles makes it difficult to insure that your vehicle model has
been accurately accounted for. In the case of any technical
discrepancies between this guide and your service manual, we
strongly advise that you adhere to the specifications and techniques
as documented in your service manual.
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. Many ARB distributors around the world have been fully
instructed in Air Locker installations by ARB, and have gained a wealth
of experience and skill from years of performing similar installations.
Once you begin this installation your vehicle will be immobile until all
steps of the installation are complete. Make sure your Air Locker kit is
the correct model for your vehicle and that it contains all of the parts
listed on back cover of this booklet. Also be sure you have
appropriately equipped yourself with all the necessary tools, parts, and
materials to complete this installation (see section 1.2 Tool-Kit
Recommendations), and that you have allowed for an appropriate
amount of vehicle down time.
HINT :
Place a
mark inside each of the c symbols as
you complete each step. It is very important NOT to
miss any of the steps!
1 Introduction
1.2
Tool-Kit Recommendations
Below is a list of tools and supplies you may need to complete this
installation. Requirements for your vehicle may vary. Please consult your
vehicle service manual for additional recommendations.
1.2.1 Tools
c Standard automotive sizes (metric and/or imperial) of sockets,
wrenches, Allen keys, and drills.
c A dial indicator or other suitable measuring tool for checking ring &
pinion backlash.
c A standard automotive feeler gauge.
c Automotive brake tubing cutters to cut the copper tubing.
c A razor knife to cut the nylon tubing.
c A differential housing spreader, to facilitate removal of the carrier.
c A torque wrench. (See vehicle service manual for required torque
range.)
c A lubricant drain reservoir.
c Suitable measuring tools to measure a differential for pre-load
and/or backlash shimming. (See Section 3 Bench Measurement)
c A 11.2mm [7/16”] drill and ¼” NPT tap for bulkhead fitting
installation.
c An automotive bearing puller (2 jawed is recommended) or a
differential carrier bearing puller.
c A bearing press or arbor press.
1.2.2 Supplies
c Thread lubricant/sealant compound for pressure fittings (e.g.,
LOCTITE #567 Teflon paste)
c Thread locking compound (e.g., LOCTITE #272)
c Either a replacement gasket, or gasket sealant.
c A sufficient volume of differential oil to completely refill your
housing. (see the ARB Air Locker Operating and Service Manual
for recommended lubricants)
c A soap and water mixture to test for air leaks.
c A selection of differential bearing shims to set-up pre-load and
backlash. (See section 3 Bench Measurement)
2 Removing the Existing Differential
2.1
Vehicle Support
c 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.
c Once supported off the ground, release the parking brake and
leave the vehicle in neutral. Chock the wheels if necessary.
2.2
Differential Fluid Drain
c Clean around the third member flange seal to prevent dirt from
entering the differential.
c Position a fluid drain reservoir under the differential.
c Remove fluid drain plug to empty all differential oil.
HINT :
2.3
This is a good time to check for metal particles in
your oil which may indicate a worn bearing or
differential component.
Removing the Axles and Differential
c Remove the axles according to your vehicle’s service manual.
c Disconnect the drive shaft from the flange of the differential.
c Remove the third member from the differential housing. (Refer to
your vehicle’s service manual)
NOTE : The differential housing is heavy and quite difficult to
handle when covered in oil. Do not drop it!
IMPORTANT :
Collision damage or heavy off-road use of your vehicle in the past may
have resulted in some degree of bending in the axle. 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.
2 Removing the Existing Differential
2.4 Marking the Bearing Caps
c Using a pointed center punch, gently mark the differential housing
and the bearing caps in a way that will enable you to correctly
position the cap during reassembly. (Fig.1.)
Figure 1.
2.5 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. Although ARB must
recommend you set backlash according to your service manual
guidelines, we also advise that you compare the backlash
measurements taken here to the recommended backlash settings
in your vehicle service manual. Measurements found to be
outside of your service manual recommendations may indicate
the need to deviate from those settings in order to achieve quiet
running with a good contact mark.
Refer to your vehicle service manual or your local authorized
ARB installer for more information.
2 Removing the Existing Differential
c Set a depth indicator on one of the ring gear teeth as in Figure 2.
Figure 2.
c 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). This value is referred to as the ring and pinion
backlash.
c Rotate the differential center 90° and measure again for accuracy.
c Record the average of all measurements.
2 Removing the Existing Differential
2.6
Spreading the Differential Housing
IMPORTANT:
Spreading the differential housing with a differential case
spreader is a step which is critical to set up bearing pre-load
when a differential is installed. Improper pre-load will result in
undue bearing wear, increased stresses in the differential center,
increased running noise, and ultimately, ring and pinion gear
damage.
c Unbolt and remove the bearing caps.
c Setup the differential spreader and a dial indicator and carefully
spread the differential housing (Fig.3.) just enough to remove the
differential carrier (Refer to your vehicle’s service manual).
NOTE : Never spread the housing more than 0.5mm [0.020”].
c Once the housing has been adequately spread, the differential may
be removed by pulling forward on the differential center.
c Remove spreader tension.
Figure 3.
3 Bench Measurement
3.1
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.
c Secure the original differential to a work bench.
c Remove the bolts that hold the ring gear in place.
c Using a plastic or copper hammer, tap in a circle around the ring
gear to separate it from the differential carrier.
c Remove the original bearings and shims from the differential center
using a bearing puller.
NOTE :
Keep the bearings and shims separated so that they
can be identified as to which end of the differential
they came from.
c Examine the bearing cups and cones from Fig. 4. for damage or
wear and, if necessary, discard them and replace with the same
size and type of bearings.
Figure 4.
3 Bench Measurement
c 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’.
c Measure the thickness of the factory shim removed from the end of
the differential carrier (shown as ‘B’ in Fig.4.) and record this
measurement as ‘B’.
Figure 5.
c Measure the distance from the Air Locker bearing shoulder to the
ring gear mounting face (shown as ‘C’ in Fig.5.) and record this
measurement as ‘C’.
3 Bench Measurement
3.2
Calculation & Selection of Shims
Ideally, the measurement you recorded as ‘C’ from the Air Locker
differential will closely match ‘A’ on the existing differential (within
0.1mm [0.004”] ) and then the factory shim can be reused, however,
quite often these measurements will vary slightly between one factory
differential and the next.
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
equation will also be true:
A + B – C – D = ZERO
c Create a shim pack to match the thickness calculated as ‘D’.
To achieve the desired shim thickness you can:
• Machine down the factory shim thickness.
• Add shims between the factory shim and the bearing cup.
HINT :
A selection of shims of this size have been supplied
with your Air Locker kit.
• Purchase new factory shims at the desired thickness.
• Use a universal shim kit available from most drive train
specialists.
• Add small amounts of shim between the bearing cone and the
bearing seat.
NOTE :
NEVER machine the Air Locker.
4 Installing the Air Locker
4.1 Installing the Carrier Bearings
c With the Air Locker well supported in an arbor press, apply a thin
film of high pressure grease to both bearing journals.
c Press one of the tapered roller bearing cones onto one of the
bearing journals of the Air Locker until the bearing seats firmly
against the bearing journal shoulder.
c Invert the Air Locker and press the second bearing cone onto the
opposite bearing journal until the bearing seats firmly against the
bearing journal shoulder.
NOTE :
4.2
Never re-use any bearings which are damaged or
worn.
Mounting the Ring Gear
c Apply a thin film of high-pressure grease to the ring gear shoulder
of the Air Locker to prevent seizing.
c 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.
NOTE :
Rubbing the ring gear mounting face with a flat oil
stone before installation will remove any high spots
around the threads.
c Heat the ring gear to between 80 and 100°C (175 - 212°F) in an
oven or in hot water to slightly expand the gear and facilitate
assembly.
NOTE :
NEVER HEAT GEARS WITH A FLAME! This could
damage the hardened surface of the gear and result in
premature wear or failure.
c Dry the ring gear with compressed air (if wet), paying particular
attention to the threaded holes.
c Install the ring gear onto the Air Locker by aligning the holes in the
flange with the tapped holes in the ring gear, then gently tapping it
around in a circle with a plastic or copper hammer.
4 Installing the Air Locker
NOTE :
Avoid using the bolts to pull down the ring gear as
this puts excess strain on the bolts and the differential
flange.
c Apply a thread locking compound to the thread of each ring gear
bolt before inserting it.
NOTE :
Do not apply threading compound directly into the
threaded hole as this could prevent the bolt from
reaching its full depth.
c Tighten the ring gear bolts in a star pattern with a torque wrench
according to your vehicle manufacturer’s specified torque.
4.3
Assembling the Seal Housing
Figure 6.
c Make sure the grooves and airway of the seal housing are clean
and free from any contaminants (e.g. water, dirt, metal filings, etc.).
c Inspect the seal housing O-rings (supplied) for dirt, damage or
other conditions which might cause leaks.
4 Installing the Air Locker
c Generously lubricate the O-rings with oil prior to assembly, then
insert them into the grooves of the seal housing.
NOTE :
When assembling the O-rings, be careful not to leave
them twisted when seated in the grooves as this could
cause excessive wear and leakage.
c Lubricate the seal housing running surface on the Air Locker carrier
with oil. Assemble the bearing cup onto the left-hand side of the Air
Locker.
c Assemble one of the two master shims (included with the Air
Locker shim kit) onto the seal housing with the rounded edge of the
shim facing out.
NOTE :
No shims other than the master shim should be
assembled onto the seal housing at this time.
c Carefully install the seal housing (master shim towards the
center) by sliding it all of the way onto the bearing journal with a
gentle twisting motion. This will allow the O-rings to engage gently.
4.4
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 6.
c Hold the bearing cup and shim pack ‘D’ (Fig.5.) in place, and insert
the Air Locker into the housing.
c Push the Air Locker hard across against the bearing and shim pack
‘D’, and measure the gap (ie. End Float) between the end of the
seal housing assembly and the bearing seat of the differential
housing with a feeler gauge.
c Consult your vehicle manufacturer’s service manual to determine
the carrier bearing pre-load amount specified for your vehicle.
c Add the specified pre-load amount to the measurement taken with
the feeler gauge to determine a shim amount for ‘E’ in Figure 6.
PRE-LOAD + END FLOAT = SHIM PACK
4 Installing the Air Locker
c Select suitable shims from the shim kit supplied with your Air
Locker to make up a shim pack of this thickness. (Refer to section
3.2 for methods of shim adjustment).
c The seal housing will have to be removed in order to add shim pack
‘E’. Ensure that the seal housing is re-installed correctly.
4.5
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.
c Mark a spot on the exterior of the differential housing toward the top
in an area that will be well clear of the Air Locker body, the ring
gear, and any other obstructions that could snag the seal housing
tube. (Fig.7.)
Figure 7.
c
c
c
c
Remove the Air Locker from the differential housing.
Cover the drive pinion area with a rag to protect it from metal filings.
Secure the differential housing to the work bench.
Drill a 11.2mm [7/16”] diameter hole through the differential housing
square to the outside surface.
c Tap the hole from the outside using ¼”NPT thread tap.
4 Installing the Air Locker
c Remove any sharp edges that may chip off from around the hole
and fall into the housing.
c Very carefully, remove the rags and inspect with a service light
inside the housing to insure no metal filings are left behind.
4.6
Modifying the Bearing Cap
c A hole must be drilled in the seal housing bearing cap for the seal
housing tube to pass through.
Figure 8.
NOTE :
Take time and double check when drilling, as bearing
caps are custom fitted to the axle housing and cannot
be replaced.
c Hold the seal housing end of the bearing cap steady for drilling in a
vice clamp.
NOTE :
Do not apply too much clamping pressure with the
vice. The bearing cap may be damaged.
c Using a pedestal drill, drill a 6mm [¼’’] hole through the bearing
cap, in the position shown, so that the drill is against the edge of
the bearing stop. (Fig.8.)
c Debur both ends of the drilled hole to remove any sharp edges.
4 Installing the Air Locker
4.7
Final Air Locker Assembly
c Spread the differential housing again (Refer to section 2.6).
c Hold shim packs ‘D’ (Refer to section 3.2) and ‘E’ (Refer to section
4.4) in position on the Air Locker.
c Reinstall the Air Locker into the differential housing, ensuring that
the seal housing is postitioned so that the tube will point straight up
through the hole in the bearing cap (Fig. 9.)
Figure 9.
NOTE :
If the carrier is too difficult to install with the added
shim pack then the spreader tension may need to be
increased. Do not spread the housing more than
0.50mm [0.020”].
c Place the bearing caps in place to align the seal housing tube with
the drilled hole.
c Relieve all tension on the housing spreader.
c Tighten all bearing cap bolts with a torque wrench to the torque
specified in your vehicle manufacturer’s service manual.
4 Installing the Air Locker
4.8 Final Backlash Checking
c Set a depth indicator on one of the ring gear teeth as in Fig. 10.
c 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). This value is referred to as the ring and pinion
backlash.
c Rotate the differential center 90° and measure again for accuracy.
Figure 10.
c Refer to your vehicle service manual for the specified maximum
and minimum amounts of backlash. If the backlash is not within the
specifications then the differential will have to be removed and reshimmed.
4.8.1 Re-Shimming the Backlash
NOTE :
c
c
c
c
This step is only necessary when adjusting for
incorrect backlash.
Reapply the spreader to the differential housing.
Remove the bearing caps.
Remove the differential.
To increase the amount of backlash, reduce the shim thickness ‘D’
(Fig.5.) and increase the shim thickness ‘E’ (Fig.6.) by the same
amount. Reverse this step to decrease the backlash.
c Remount the differential as before.
c Release spreader tension.
c Check backlash again as before.
4 Installing the Air Locker
4.9
Profiling the Seal Housing Tube
The seal housing tube will need a profile that hugs the Air Locker and
the bearing cap in order to ensure clearance with the axle case when
reinstalled into the axle assembly.
c Without using sharp, jagged tools such as pliers (usually your
hands are the best tool for this job), bend the seal housing tube so
that it closely follows the bearing cap brace and protrudes through
the bulkhead port in the differential housing (refer to Fig. 11.).
c Trim the tube to length using automotive brake line cutters.
Figure 11.
c Check that the contour of the tube will not interfere with the Air
Locker or the ring gear.
c Cable tie the tube to the bearing cap brace (Fig. 11.).
4.10
Setting up the Bulkhead Fitting
c Apply thread sealant to the threads of the bulkhead body.
c Screw the bulkhead body into the tapped hole, and tighten.
c Wipe the area clean of any excess thread sealant (inside and
outside of the housing).
4 Installing the Air Locker
c From the outside of the housing, assemble the small O-ring over
the top of the short length of seal housing tube protruding through
the bulkhead fitting.
c While holding the seal housing tube into the bulkhead fitting, insert
the small drilled end of the center compression nut over the
extended tube as shown in the assembly diagram (Fig.12.), and
screw it into the bulkhead body, and lightly tighten.
NOTE :
Be sure to insert the correct end of the center
compression nut into the bulkhead body. The thread
has been partially relieved on the bulkhead side of the
center compression nut to visually identify its
orientation. (Fig.12.)
Figure 12.
NOTE :
Excessive tightening of the center compression nut is
not necessary to form a good seal around the tube
and may damage the O-ring, the seal housing tube, or
the threads of the compression nut.
NOTE :
Make sure the seal housing tube is all of the way into
the center compression nut while you are tightening
it.
4 Installing the Air Locker
c Check that no part of the seal housing tube comes in contact with
the moving differential components. 10mm [3/8”] should be
considered adequate clearance. Gently bend the tube away from
moving parts if necessary.
4.11
Bench Testing the Air Locker
c To test the Air Locker; when 620kPa [90 PSI] shop air is applied to
the seal housing tube, the Air Locker should engage.
c Check all fittings and the seal housing for air leaks.
c Rotate the differential carrier by turning the pinion flange whilst
applying air pressure.
NOTE : An accurate way to test for air leaks is to fit a shut-off
valve to an air pressure gauge (ARB part # ALTG01).
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. If so, this will indicate an air leak.
(Fig.13.)
Figure 13.
c If a leak is found to be present, spray a soap and water mixture
onto the bulkhead air fitting. Bubbles should appear at any leak
points.
NOTE :
Do not spray this soapy mixture inside the differential.
c Check that leaky fittings have been adequately tightened.
c Disassemble, clean threads, and reapply thread sealant if leaking
persists.
4 Installing the Air Locker
c If a leak is found at the seal housing, carefully remove the seal
housing assembly and examine the O-rings. Be very careful with
the O-rings and check for defects, damage, wear, or presence of
foreign material in the O-ring grooves. Replace if necessary.
4.12
Reinstalling the Differential and Axles
c Reinstall the third member to the differential housing according to
your vehicle service manual.
c Reinstall the drive shaft.
c Replace the axle seals if necessary and fit to the axles.
c Insert both axles fully into the housing, engaging splines, and then
gently tap them inward.
NOTE :
Be careful not to damage the axle shaft oil seals when
installing the axle. Support the axle’s entire weight
where possible.
c Torque down the axle bolts to manufactures specifications.
5
Installing the Air System
5.1
Mounting the Solenoid
5.1.1
Connection to an ARB Air Compressor (Fig.14.)
c Remove one of the 1/8” BSP plugs from its port in the compressor
tank.
c Apply Teflon paste to the nipple (1/8” X 1/8” BSP) and insert it into
the port and tighten.
c Apply Teflon paste to the free end of the nipple.
c Assemble the inlet port side of the solenoid (stamped with a ‘1’)
onto the nipple and tighten. The solenoid should be rotated into a
position that does not obstruct any other ports on the compressor
tank.
NOTE :
The solenoid exhausts compressed air through the
center of the black retaining cap when the Air Locker
is disengaged. Make sure this orifice cannot be
obstructed.
c Apply Teflon paste to the threads of the 5mm push-in fitting and
assemble it into the solenoid outlet port (stamped “2”) and tighten.
ARB
Air Compressor
Figure 14.
5
Installing the Air System
5.1.2
Connection to an Alternate Air Source
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:
c Must supply a minimum of 85PSI [586kPa].
c The supply must never exceed 105PSI [724kPa].
c The Air source should have a tank capacity that enables it to
actuate the Air Locker(s) in one charge so that no hesitation
is experienced when locking one or two differentials.
HINT :
A good way to insure that you have the
necessary capacity is to make sure you can
engage, disengage, and then reengage your Air
Locker(s) without the air source having to
regenerate (e.g., without the compressor turning
on to refill the tank).
c Must supply clean air, free of rust, dirt, water, or other foreign
matter.
c Must match the 1/8” BSP porting of the Air Locker solenoid.
c Mount solenoid within close proximity of the air supply and secure it
from the effects of vibration and shock.
c Connect the air supply to the 1/8” BSP inlet port of the solenoid
(stamped “1” on the solenoid body) using thread sealant.
IMPORTANT :
ARB cannot warrant your Air Locker(s) against damage caused
as a result of using an alternate air supply. If you have any
doubts as to the suitability of your air system to use in an Air
Locker system, consult your ARB distributor.
5
Installing the Air System
5.2
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:
c Account for axle travel when running the line from the axle to a
fixed point on the vehicle. Leave enough slack in the air line to
allow for maximum suspension travel in both directions.
c Avoid leaving large lengths of air line hanging underneath the
vehicle where they may get tangled on rocks, sticks, etc.
HINT :
c
c
c
c
c
c
c
Cable tying the air line to one of your flexible brake
lines will account for axle travel and should help keep
your line from getting snagged.
Run the air line all the way from the compressor to the differential
before trimming either end of the line to length. This will save
complications that may arise if the air line has to be removed.
Make sure the line does not contact sharp edges or abrasive
surfaces that may damage the air line over time.
Do not run the air line around tight bends which may kink the air
line and restrict or block the air flow.
Keep the air line well away from your vehicle’s exhaust
components. Air lines will melt if subjected to extreme heat.
Do not run more air line than necessary. Excess line volume
created when coiling the left over hose, using unusually large
diameter hose, etc., will increase drain on the compressor tank
resulting in the compressor running more often than needed.
Support the air line by tying it back with cable ties wherever
possible.
At the solenoid end of the air line, trim the line to length with a
sharp knife.
NOTE :
To remove the air line from the push-in fitting; while
holding the flange of the fitting out, push the air line
into the fitting as far as possible, then press the flange
inward, then pull the air line free of the fitting.
c 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.
5
Installing the Air System
5.3
Connection to the Bulkhead Fitting
c Trim the air line to length using a sharp knife.
c Insert the support spring over the end of the air line - small end first.
(Fig.15.)
c Insert the outer compression nut over the air line.
c Insert the 5mm [0.197”] ferrule over the end of the air line. Leave
approx. 5mm of tubing between the ferrule and the end of the tube.
Figure 15.
c Insert the support tube all the way into the end of the air line.
HINT :
c
c
c
c
If the support tube is too difficult to insert, place the
end of the air line into a cup of boiled water to soften
the tubing.
Insert the tube end all the way into the center compression nut.
Screw on the outer compression nut and tighten. The ferrule and
support tube are now permanently attached.
Assemble the support spring over the outside of the outer
compression nut.
Secure any loose sections of tube with a cable tie.
6 Mounting & Connecting the Electrical System
6.1
Mounting the Actuator Switch(es)
Air Locker actuator switch(es) can be easily panel mounted inside the
vehicle in a 21mm x 36.5mm [0.83” x 1.44”] rectangular cutout.
NOTE : Only attach the cover plate to the face of the switch
once the switch has been mounted and wired correctly
as the cover plates are designed to be difficult to
remove.
For reasons of safety and for ease of operation, the Air Locker
actuator switch(es) should be mounted in a location picked to best suit
the operator. Make sure you have taken the following points into
consideration:
c Switch(es) MUST be mounted and should never be allowed to
simply dangle from the wiring loom during vehicle use.
c Switch(es) should be within easy reach of the driver. Ideally, any
Air Locker switch should be able to be operated without physical
effort or distraction to the driver.
c Switch(es) should be mounted within the line of sight of the driver
so that switch position (‘ON’ or ‘OFF’) can be visually determined
by the rocker position and the illumination state.
c The position of the switch(es) should best eliminate any possibility
of accidental operation by the driver or one of the passengers.
c Switch cutout position(s) must be located in an area with a
minimum of 50mm [2”] of clearance behind the face of the cutout.
c Switch(es) should not be mounted where they will be exposed to
water (e.g., in the lower section of an inner door panel).
c ARB recommends that you apply the Air Locker Warning Sticker
(ARB part # 210101) within close visual proximity of the switch
location.
NOTE :
If no adequate position can be found on existing
dashboard panels, a surface mounted bracket
(Fig.16.) may be purchased from your ARB Air Locker
distributor to suit 1, 2, or 3 switches.
6 Mounting & Connecting the Electrical System
Figure 16.
6.2
6.2.1
Wiring the Actuator System
Connection to an ARB Air Compressor
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.17.)
NOTE : 180405 & 180409 model looms shown for reference
only. Refer to your ARB Air Compressor Installation
Guide for details on configuring your installation.
6 Mounting & Connecting the Electrical System
180405
Figure 17.
180409
6 Mounting & Connecting the Electrical System
SWITCH
TERMINAL
IDENTIFICATION
UP
Figure 18.
6.2.2
Connection to an Alternate Air Source
When connecting the actuation switch to an alternate air source, the
switch(es) should be wired according to Figures 19. and 20.,
depending on whether one or two Air Lockers will be installed in the
vehicle.
6.2.2.1 Single Air Locker System
c If only one Air Locker is to be installed in the system, the switch and
solenoid should be wired according to Figure 19. regardless of
whether the Air Locker has been installed in the front or rear axle of
the vehicle.
c Attach the appropriate switch cover (i.e., ‘FRONT’ or ‘REAR’) to the
switch.
NOTE :
Refer to Figure 18. for the correct switch terminal
identification and switch orientation.
SINGLE Air Locker SYSTEM
Figure 19.
6 Mounting & Connecting the Electrical System
6.2.2.2
Dual Air Locker System
c If two Air Lockers are to be installed in the system, ARB
recommends that the switches and solenoids be wired according to
Figure 20. For safety reasons, this configuration allows SOLENOID
2 to be actuated only if SOLENOID 1 is already on.
c Attach the “REAR AIR LOCKER” switch cover to SWITCH 1, and
the “FRONT AIR LOCKER” switch cover to SWITCH 2.
NOTE :
Refer to Figure 18. for the correct switch terminal
identification and switch orientation.
c Configure SOLENOID 1 as the air line leading to the rear axle Air
Locker, and SOLENOID 2 as the air line leading to the front axle Air
Locker.
DUAL Air Locker SYSTEM
Figure 20.
7
7.1
Testing & Final Assembly
Leak Testing
c 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.
c Actuate the Air Locker(s).
c The compressor should not come on again for a period of at least
15min. Air system recharging within that time period would indicate
that a leak is present in the system.
NOTE :
If an alternate air source (e.g., an air cylinder or a belt
driven air pump) is used instead of a compressor, the
air system will have to be leak tested with a pressure
gauge and a shut-off valve in series before the
solenoid input.
c If a leak is found to be present, spray a soap and water mixture
onto all air fittings in the system while the compressor is fully
charged. Bubbles should appear at any leak points.
c Check that leaky fittings have been adequately tightened.
c Disassemble, clean threads, and reapply thread sealant if leaking
persists.
7.2
Testing the Air Locker Actuation
To test that your air system, electrical system, and your Air Locker
differential is functioning correctly:
c Support the vehicle such that the wheels are free to rotate (e.g., on
axle stands, a chassis hoist, etc.)
c Leave the parking brake off, the transmission in neutral, and the Air
Locker switch ‘OFF’.
c Turn the ignition to the ‘ON’ position (leaving the motor off). The
large illuminating symbol on the Air Locker switch cover should be
‘OFF’.
c Turn the compressor (or alternate air source) on to charge the air
supply up to its maximum pressure.
7
Testing & Final Assembly
c Rotate one wheel by hand.
c The wheel should rotate freely and the opposite wheel should be
turning in the opposite direction without any resistance or
mechanical noise from within the differential.
c Turn the Air Locker switch to the ‘ON’ position. The illuminated
symbol on the switch cover should light up.
c Rotate the same wheel again.
c Both wheels should rotate together.
c Turn the switch off again.
c Rotate the same wheel.
c The wheels should again rotate in opposite directions.
7.3
Filling the Differential
NOTE :
c
c
c
c
c
Consult the ARB Air Locker Operating & Service
Manual for recommendations on differential lubricant
specifications.
Remove the filler plug.
Refill the differential until level with the filler hole.
Rotate the differential center 2 full turns.
Check the oil level and add oil if necessary.
Replace filler plug (apply thread sealant to filler plug before
inserting if it is a threaded type plug).
c Wipe differential housing clean of any oil or grease which may
collect dirt or other abrasive particles.
7
7.4
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.
c The air system has been leak tested.
c Thread locking compound was used on the ring gear bolts.
c All torque settings comply with the vehicle manufacturer’s specs
and were set with an accurate torque wrench.
c Differential fluid complies with ARB recommendations and has
been filled to the correct level.
c All air lines and wiring have been securely cable tied to resist
snagging.
c Switch(es) have been securely mounted within operator reach, yet
well away from danger of accidental engagement.
c Switch(es) function properly and illuminate to indicate that Air
Locker(s) are engaged.
c All operators who are to use the Air Locker have read, and fully
understand the ARB Air Locker Operating & Service Manual.
c The Air Locker Warning Sticker has been located within close
proximity of the actuator switch(es).
INSTALLATION PERFORMED BY:
___________________________
DATE OF INSTALLATION:
___________________________
ODOMETER READING:
___________________________
ARB AIR LOCKER SERIAL No:
___________________________
8
Parts List
8.1 Exploded Assembly Diagram
Figure 21.
(See itemized parts list overleaf)
8
Parts List
8.2 Itemized Parts List
(See exploded diagram figure 21.)
AIR LOCKER MODEL No. :
ITEM #
QTY
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
*
*
*
*
*
*
*
*
*
*
*
*
*
2
1
1
1
1
1
1
1
2
3
2
1
8
1
2
4
4
2
1
1
1
1
1
1
1
1
10
2
1
1
1
1
*
ARB PERFORMANCE CLUTCHES
RD129
DESCRIPTION
SEAL HOUSING O-RING
SEAL HOUSING ASSEMBLY
SHIM KIT
BONDED SEAL
CLUTCH GEAR
SPIDER BLOCK
LONG CROSS SHAFT
SIDE GEAR
COUNTERSUNK SCREWS
CROSS SHAFT RETAINING PIN
TAPERED ROLLER BEARING
FLANGE CAP ASSEMBLY
RETURN SPRING
SPLINED SIDE GEAR
SHORT CROSS SHAFT
PINION GEAR
PINION THRUST WASHER
SIDE GEAR THRUST WASHER
DIFFERENTIAL CASE
BULKHEAD FITTING KIT (O-RING TYPE)
PUSH-IN FITTING (5mm to 1/8” BSPP)
AIR LINE (5mm DIA X 6m LONG)
NIPPLE, (1/8” to 1/8” BSPT)
SOLENOID VALVE (12V)
SWITCH
SWITCH COVER (REAR)
CABLE TIE
CABLE TIE (4.8 x 200mm)
WARNING LABEL
BUMPER STICKER
OPERATING & SERVICE MANUAL
INSTALLATION GUIDE
PART #
160207
081807
SHK004
160702
050806
070201
060204
131311R
200213
120601
NOT SUPPLIED
027313
150113
131411R
060403
140701R
151110
151010
013013
170105
170201
170301
170501
180103
180209
180211
180301
180302
210101
210102
210200
2102129
Not illustrated in exploded view.
TRANSMISSION AND DRIVETRAIN
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