ARB RD105 User Manual

RD10

5

DANA 35,

30

SPLINE, 3.54 & UP

INSTALLATION GUIDE

Part No. 2102105

Revision Date 16/03/04

Copyright © 2004 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 Central 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 28

5 Mounting & Connecting the Electrical System 33

6 Testing & Final Assembly 38

Assembly Type Identification 5

2.1

Vehicle Support 6

2.2

Differential Fluid Drain 6

2.3

Removing 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 14

3.3

Approximate Backlash Shimming 15

3.4

Mounting the Ring Gear 17

3.5

Drilling and Tapping the Bulkhead Port 18

3.6

Assembling the Seal Housing 19

3.7

Pre-Load Shimming 20

3.8

Reinstalling the Bearing Caps 23

3.9

Checking the Backlash 24
Setting Up the Bulkhead Fitting 25
Profiling the Seal Housing Tube 27

4.1

Mounting the Solenoid 28

4.2

Running & Securing the Air Line 30

4.3

Connection to the Bulkhead Fitting 31

5.1

Mounting the Actuator Switch(es) 33

5.2

Wiring the Actuator System 34

6.1

Leak Testing 38

6.2

Reinstalling the Axles 38

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.
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

‘C’ CLIP

1.3 Assembly Type Identification

IMPORTANT:

Sections 2 and 6 of this installation guide have been written to
accommodate two different Dana 35 applications:

A The ‘C’ clip retained axle shaft (Refer to Fig.1.)
B the non-‘C’ clip type axle shaft (Refer to Fig.2.)

To eliminate confusion, you should identify which figure your axle
matches with. The section numbers within the guide that refer ONLY
to the ‘C’ clip type have been suffixed with an ‘ A ’, and those that refer
ONLY to the non-‘C’ clip 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.

c Clean any loose dirt from around the differential cover flange area,

the filler plug area, and the drain plug (if any) to avoid
contaminating the differential cavity with abrasive particles.

c Position a fluid drain reservoir under the differential.
c If a drain plug exists, remove it and completely drain all differential

oil from the housing.

c If no drain plug exists then the oil can be drained by loosening the

cover bolts and gently prying the cover away at the bottom until oil
runs out.

HINT : If a drain plug does not exist then it would be a good

idea to drill and tap for a tapered oil drain plug to assist
with future oil changes.

c Once drained, remove the differential cover plate.

6

2 Removing the Existing Differential

2.3 Removing the Axles

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

2.3.1 A Removing ‘C’ Clip Retained Shafts

c Remove both of the rear wheels and brake drums/rotors according

to you vehicle manufacturer’s service manual.

c Rotate the differential carrier using the drive shaft until you have

clear access to the cross shaft retaining pin.

installing your Air Locker.

c Completely remove the retaining pin by unscrewing it.
c Rotate the differential carrier again until you can completely remove

the cross shaft from the differential.

c Tap the axle shafts inward to unseat the ‘C’ clips from their pockets

in the center of the differential side gears.

c Using needle nosed pliers, remove both ‘C’ clips from the

differential.

c Tap the axle shafts outward until the splines are disengaged from

the differential side gears.

c Gently slide the axle shafts out of the axle tubes until they can be

completely removed from the vehicle.

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

Support the weight of the axle shafts when drawing
them out of their sockets in the housing.

2.3.2 B Removing Non-‘C’ Clip Semi-Floating Shafts

c Remove both of the rear wheels and brake drums/rotors according

to your vehicle manufacturer’s service manual.

c Remove the axle retaining nuts holding the retaining plate to the

axle tube assembly.

NOTE : The axle retaining nuts and bolts are not

recommended for re-use and should be re-placed at
the time of reassembly.

7

2 Removing the Existing Differential

c Pull the axle free of the axle bearing using a slide hammer.
c Gently slide the axle shafts out of the axle tubes until they can be

completely removed from the vehicle.

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

Support the weight of the axle shafts when drawing

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

them out of their sockets in the housing.

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

IMPORTANT:

YOU MUST SPREAD THE HOUSING ON DANA 35 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 Dana 35 differential housings. 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”].
NOTE : Be sure not to mix up the left and right hand bearing

cups and master shims. Later it will be necessary to
know which cup and shim 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.

10

3 Installing the Air Locker

3.1 Insuring Adequate Oil Drainage

IMPORTANT:

Some 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

points are present in the differential housing then it is critical

that you modify the housing to include them.

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 exists then two slots should be created in the bearing

seat face of both axle tubes; one on the upper side of the tube, and
one on the lower side. Figure 7. shows an example of an axle
housing with no existing oil drainage.

11

3 Installing the Air Locker

Figure 7.

Figure 8.

NOTE : Cover the differential housing cavity and the axle tube

openings with a rag to protect them from metal filings.

12