ARB 0750001B User Manual

INSTALLATION GUIDE

ARB DIFFERENTIAL COVER

Part No. 21020751

Revision Date 10/09/10

Copyright © 2007 by ARB Corporation Limited

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.

ARB 4x4 ACCESSORIES

Corporate Head Office

42-44 Garden St Tel: [phone]
Kilsyth, Victoria Fax: [phone]
AUSTRALIA
3137

Australian enquiries [e-mail]
North and South American enquiries [e-mail]
Other international enquiries [e-mail]

www.arb.com.au

1 Introduction

ARB DIFFERENTIAL COVERS

1.2 Model Range

• Available for most standard Dana 60, Dana 44, Dana 35, and
Dana 30 axle assemblies.

ARB Part # APPLICATION(s)

0750001 Dana 60 and Land Rover Salisbury
0750002 Dana 30
0750003 Dana 44
0750004 Dana 35 and Dana 35C

1.2 Features

• High tensile solid nodular iron structure (tougher and harder
than solid carbon steel) protects the differential and ring &
pinion set from the obstacle impact hazards of competition
rock crawling, or extreme off road trails.

• Computer optimized cross brace design adds more than 1300
Nm/deg [960 ft-lb] of torsional rigidity to the entire axle
assembly. This increased flexural strength in the housing
helps keep the ring & pinion gears meshing on the flat faces of
the teeth, which greatly increases ring & pinion life and overall
maximum load strength.

• Carrier bearing life is prolonged, especially on high output
vehicles, by the improved support given to the bearing
alignment.

• Low-profile shape of the outside surface helps maximize the
running gear clearance around the cover.

• Maximized approach / departure angled exterior surfaces help
to minimize rock / obstacle hang-ups.

• High tensile cap screws (supplied with the kit) are recessed
into the cover to protect them from contact with obstacles
which might damage or loosen them.

• Low profile drain plug design resists damage from obstacle
contact.

1 Introduction

Note: Most of the standard Dana Spicer Salisbury type

axles do not come factory equipped with oil drain
plugs of any kind, and therefore the cover must
usually be pried away from the housing in order to
expel the oil. This can be very messy, and if you
only wanted to sample the oil for contamination it
can be very wasteful.

• Unique dipstick / filler cap design allows differential oil level to
be adjusted higher for customized high driveline angles
(i.e., raised vehicles with partially rotated differential
housings).

• Combination of the high filler point and dipstick allows the oil
to be checked for water contamination (i.e., grey foam) without
having to drain the oil (i.e., without losing any oil on the trail).

• Top quality high power neodymium magnets (rare earth) are
used in both the drain plug AND the dipstick to collect metallic
wear particles as the vehicle moves.

• Magnet location in the end of the dipstick allows the oil to be
checked for tell-tale signs of internal damage
(e.g., metal debris from ring & pinion or carrier bearing
damage) without having to drain the oil.

• Covers are colour powder coated, CNC machined, and then
clear coated for a durable, professional, long lasting finish. All
hardware is corrosion protected.

• 350% improvement in the looks of your vehicle from

underneath!

1.3 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.

F Standard automotive sizes (metric and/or imperial) of sockets,

wrenches, Allen keys, and drills.

F A torque wrench.
F A lubricant drain reservoir.
F Either a replacement gasket, or gasket sealant (such as Loctite

587).

F A sufficient volume of differential oil to completely refill your

housing. (see the ARB Air Locker Operating and Service Manual
for recommended lubricants)

2 Installation

2.1 Differential Fluid Drain

HINT : This is a good time to check for metal particles in

your oil, on your drain plug, or in the bottom of the
housing which may indicate a worn bearing or

F Clean any loose dirt from around the differential cover to avoid

contaminating the differential cavity.

F Position a fluid drain reservoir under the differential and loosen

all differential cover plate retaining bolts.

F Gently pry the cover plate away from the differential housing to

completely drain all differential fluid.

F Once drained, remove the differential cover.

2.2 Determining Oil Level

The following is a guideline to determine the correct differential oil
level in an axle with the standard driveline angle.

F Place the ARB Differential Cover on a bench next to the standard

differential cover that you have removed from the vehicle.

differential component.

F Using a straight edge (electrical tape does a great job), make a

line from the bottom of the standard cover’s filler hole to the
corresponding point on the ARB Differential Cover.

F Hold the Dipstick/Filler Cap on the outside of the ARB Differential

Cover so that it is sitting in the position it would be if it was just
placed in the filler hole. From this you can determine how far up
the dipstick the oil level should be. As can be seen in the
following picture, for this differential we would fill it up to half way
between the first and second notch.

2 Installation

2.3 Installing the new Differential Cover

IMPORTANT :

These covers have been designed for use with the most

commonly available versions of the axle assemblies listed on

the model range. Some modifications, such as grinding the

differential cover or re-routing the brake lines, may be required

for fitment to some applications.

F Clean all oil residue off the differential housing.
F Place the ARB Differential Cover in position on the differential

housing to ensure adequate clearance to surrounding
components.

NOTE : Checking for clearance between diff cover and all

NOTE : Due to inconsistent tapping depths on the factory

F Apply gasket sealant, or a replacement gasket to the flange of

the differential housing.

internal parts is crucial before tightening the cover
bolts. Failure to do this may cause damage to your
differential.

axle housings, it may be necessary to tap the
threads deeper, or slightly shorten some of the
bolts. Check that the supplied bolts will clamp down
on the diff cover properly.

F Install the ARB Differential Cover onto the housing and screw in

the bolts.

NOTE : Dana 60 differentials utilise 3/8” UNC Cap Screws

which must be torqued to 61.6Nm [45.4ft-lb]. Dana
30, 35 and 44 differentials utilise 5/16” UNC Cap
Screws which must be torqued to 34.5Nm [25.4ft-lb].

NOTE : Land Rover Salisbury models require the use of

metric M10 Cap Screws (not included). Use torque
settings to suite the grade of cap screw purchased.

F Tighten each bolt to the required torque.
F Install the drain plug and hand tighten using an 8mm Allen Key.
F Using the dipstick to check the oil level, fill the differential with the

appropriate oil to the required level, ensuring not to overfill.

F Install the filler plug/dipstick and hand tighten with an 8mm Allen

Key.

3 Parts List

3 Parts List

ARB Differential Cover – Dana 60 #0750001

ITEM # QTY DESCRIPTION PART #

01 1 D60 DIFFERENTIAL COVER 0750101
02 4 3/8” x 1.5” CAP SCREW 0750401
03 6 3/8” x 0.75”CAP SCREW 0750402
04 1 MAGNETIC DRAIN PLUG ASSY 0750201
05 1 MAGNETIC FILLER PLUG ASSY, 139mm 0750205
06 1 DRAIN PLUG O-RING 160244
07 1 FILLER PLUG O-RING 160245
08 1 INSTALLATION GUIDE 21020751

ARB Differential Cover – Dana 30 #0750002

ITEM # QTY DESCRIPTION PART #

01 1 D30 DIFFERENTIAL COVER 0750102
02 4 5/16” x 1.5” CAP SCREW 0750403
03 6 5/16” x 0.75”CAP SCREW 0750404
04 1 MAGNETIC DRAIN PLUG ASSY 0750201
05 1 MAGNETIC FILLER PLUG ASSY, 113mm 0750203
06 1 DRAIN PLUG O-RING 160244
07 1 FILLER PLUG O-RING 160245
08 1 INSTALLATION GUIDE 21020751

ARB Differential Cover – Dana 44 #0750003

ITEM # QTY DESCRIPTION PART #

01 1 D44 DIFFERENTIAL COVER 0750103
02 4 5/16” x 1.5” CAP SCREW 0750403
03 6 5/16” x 0.75”CAP SCREW 0750404
04 1 MAGNETIC DRAIN PLUG ASSY 0750201
05 1 MAGNETIC FILLER PLUG ASSY, 113mm 0750203
06 1 DRAIN PLUG O-RING 160244
07 1 FILLER PLUG O-RING 160245
08 1 INSTALLATION GUIDE 21020751

ARB Differential Cover – Dana 35 #0750004

ITEM # QTY DESCRIPTION PART #

01 1 D35 DIFFERENTIAL COVER 0750104
02 4 5/16” x 1.5” CAP SCREW 0750403
03 6 5/16” x 0.75”CAP SCREW 0750404
04 1 MAGNETIC DRAIN PLUG ASSY 0750201
05 1 MAGNETIC FILLER PLUG ASSY, 100mm 0750202
06 1 DRAIN PLUG O-RING 160244
07 1 FILLER PLUG O-RING 160245
08 1 INSTALLATION GUIDE 21020751