ARB RD104 User Manual

RD104

DANA 30, 30 SPLINE, 3.73 & UP

INSTALLATION GUIDE

Copyright © 2002 by ARB Corporation Limited

Part No. 2102104

Revision Date 08/04/03

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

Table of Contents:

1 Introduction 3

1.1

Pre-Installation Preparation 3

1.2

Tool-Kit Recommendations 4

1.3

2 Removing the Existing Differential 6

3 Installing the Air Locker 12

3.10

3.11

4 Installing the Air System 30

5 Mounting & Connecting the Electrical System 35

6 Testing & Final Assembly 40

Assembly Type Identification 5

2.1

Vehicle Support 6

2.2

Differential Fluid Drain 6

2.3

Disconnecting the Axles 7

2.4

Marking the Bearing Caps 8

2.5

Checking the Current Backlash Amount 9

2.6

Removing the Differential Center 10

3.1

Insuring Adequate Oil Drainage 12

3.2

Installing the Carrier Bearings 13

3.3

Approximate Backlash Shimming 14

3.4

Mounting the Ring Gear 16

3.5

Drilling and Tapping the Bulkhead Port 17

3.6

Assembling the Seal Housing 19

3.7

Pre-Load Shimming 20

3.8

Reinstalling the Bearing Caps 25

3.9

Checking the Backlash 26
Setting Up the Bulkhead Fitting 27
Profiling the Seal Housing Tube 29

4.1

Mounting the Solenoid 30

4.2

Running & Securing the Air Line 32

4.3

Connection to the Bulkhead Fitting 33

5.1

Mounting the Actuator Switch(es) 35

5.2

Wiring the Actuator System 36

6.1

Leak Testing 40

6.2

Reinstalling the Axles 40

6.3

Testing the Air Locker Actuation 41

6.4

Re-Sealing & Filling the Differential 41

6.5

Post-Installation Check List 42

7 Parts List 43

7.1

Exploded Assembly Diagram 43

7.2

Itemized Parts List 44

1

2

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!

3

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, Alan keys, and drills.

c A dial indicator or other suitable measuring tool for checking ring &

pinion backlash.

c A standard automotive feeler gauge.
c A razor knife to cut the nylon tubing.
c A differential housing spreader, to facilitate removal of the carrier.

(not required on aluminum housings)

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 3.3)

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, for your differential

cover.

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 Teflon paste.

4

1 Introduction

A

B

1.3 Assembly Type Identification

IMPORTANT:

Sections 2 and 3 of this installation guide have been written to
accommodate two different Dana 30 applications:

A the Independent Front Suspension (IFS) type with an

aluminum housing (Refer to Fig.1.)

B the live axle Salisbury type with a cast iron housing.

(Refer to Fig.2.)

To eliminate confusion, you should identify which figure your vehicle
matches with. The section numbers within the guide that refer ONLY
to the IFS type have been suffixed with an ‘ A ’, and those that refer
ONLY to the live axle type have been suffixed with a ‘ B ’.

PLEASE IGNORE ALL SECTIONS WHICH

DO NOT APPLY TO YOUR APPLICATION

Figure 1.

Figure 2.

5

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

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
differential component.

2.2.1 A IFS Fluid Drain

c Remove any skid plates covering the bottom of the front axle area

and position a fluid drain reservoir under the differential.

c Remove the threaded drain plug and completely drain all differential

oil from the housing.

c Finger-tighten the drain plug back in to prevent drips during the

removal of the axle assembly.

2.2.2 B Live Axle Fluid Drain

c Clean around the differential cover plate seal to prevent dirt from

entering the differential.

c Position a fluid drain reservoir under the differential and loosen all

differential cover plate retaining bolts.

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

completely drain all differential fluid.

c Once drained, remove the differential cover plate.

6

2 Removing the Existing Differential

2.3 Disconnecting the Axles

2.3.1 A IFS CV Shafts

c Remove the wheels, and brakes according to your vehicle

manufacturer’s service manual.

c Disconnect the drive shaft from the differential drive flange.
c Disconnect the struts (shocks) from the lower control arms.
c Remove the forked strut mounts off of the bottoms of the strut

cylinders.

c Disconnect the upper and lower ball joints.
c Tap the CV shafts outward to disconnect the retaining clips, and

draw the knuckle joints outward until you can completely disengage
the spline of the CV shafts from the differential housing.

NOTE : The oil seals are delicate and can be easily damaged.

Support the weight of the CV shaft when drawing them
out of their sockets in the housing.

c Completely remove the differential assembly from the vehicle.
c Secure the differential assembly to a work bench.
c Remove the front access cover plate.

2.3.2 B Live Axle CV Shafts

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

c Remove the wheels, and brakes according to your vehicle

manufacturer’s service manual.

installing your Air Locker.

c Disconnect the drive shaft from the differential drive flange.
c Disconnect the upper and lower ball joints.
c Draw the knuckle joints outward until you can completely disengage

the spline of the CV shafts from the differential housing.

NOTE : The oil seals are delicate and can be easily damaged.

Support the weight of the CV shaft when drawing them
out of their sockets in the housing.

7

2 Removing the Existing Differential

2.4 Marking the Bearing Caps

c Using a 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.3.)

HINT : Many installers choose to make one punch mark on

the left hand side of the left hand bearing cap and one
similar punch mark on the housing at close proximity to
the cap mark. The right hand side is then designated
with two punch marks on the right hand side of the cap
and two similar punch marks on the housing.

Figure 3.

8

2 Removing the Existing Differential

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.

c Set a depth indicator on one of the ring gear teeth as in figure 4.

Figure 4.

c 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). 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.

9

2 Removing the Existing Differential

2.6 Removing the Differential Center

2.6.1 A Cast Aluminum Housings

IMPORTANT:

YOU MUST NOT SPREAD THE HOUSING ON

ALUMINUM IFS ASSEMBLIES.

IFS models like the Jeep Liberty (KJ) were made with an

aluminum differential housing (See Figure 1.) and therefore must

not be spread like a cast iron housing. Spreading an aluminum

housing could cause irreparable damage to the housing and is

therefore strongly advised against.

c Remove both bearing caps.
c Carefully remove the differential center by pulling or prying forward.

NOTE : Keep track of which shims came from which side as it

will be important to match them to their original
positions for measurements later.

NOTE : The differential center is heavy and quite difficult to

handle when covered in oil. Take care not to drop it.

2.6.2 B Cast Iron Housings

IMPORTANT:

YOU MUST SPREAD THE HOUSING ON CAST IRON MODELS

Spreading the differential housing with a differential case

spreader is a step which is critical to set up bearing pre-load on

cast iron differential housings (See Figure 2.). 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 Remove both bearing caps.
c Carefully spread the housing (Fig.5.) enough to remove the

differential center. (Refer to your vehicle’s service manual).

NOTE : Do not spread the housing more than 0.50mm [0.020”].

10

2 Removing the Existing Differential

HINT : Be sure not to mix up the left and right hand bearing

cups. Later it will be necessary to know which cup
came from which side.

c Once the housing has been adequately spread, the differential may

be removed by pulling forward on the differential carrier.

Figure 5.

NOTE : The differential center is heavy and quite difficult to

handle when covered in oil. Take care not to drop it.

c Relieve any tension on the spreader immediately after the

differential has been removed.

11

3 Installing the Air Locker

3.1 B Insuring Adequate Oil Drainage

IMPORTANT:

Some Salisbury axles were manufactured with poor oil drainage

between the axle tubes and the differential housing. This can

often result in one of the axle tubes filling up with differential oil

while running. In most cases this will result in a blocked air vent

which will cause the differential housing to pressurize and expel

oil from the axle seals at the wheels or force oil into the air

system of the Air Locker, eventually expelling oil at the solenoid

valve. This is a design flaw which was corrected by most

automakers in the later releases of their axle assemblies. If no

lower drainage point is present in the differential housing then it

is critical that you modify the housing to include one.

c Inspect the differential housing for the presence of adequate

drainage in both axle tubes (refer to Fig.6.).

Figure 6.

c If no drainage slot is present at the left-hand side (refer to Fig.6.) of

the housing at all, then a slot will have to be created as clearance
for the seal housing tube (Refer to Section 3.8 Reinstalling the
Bearing Caps).

c If drainage exists but is inadequate then a slot or hole should be cut

into the housing on the lower side of the tube(s) to allow oil out of
the axle tube area.

12