ARB RD132 User Manual

INSTALLATION GUIDE

50mm CARRIER BEARING

TOYOTA 8”,

Copyright © 2006 by ARB Corporation Limited

RD132

Revision Date 18/09/2008

Part No. 2102132

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.

ARB 4x4 ACCESSORIES

Corporate Head Office

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

Australian enquiries [e-mail]
North & 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

2 Removing the Existing Differential 5

2.1 Vehicle Support 5

2.2 Differential Fluid Drain 5

2.3 Removing the Axles 5

2.4 Marking the Bearing Caps 6

2.5 Checking the Current Backlash Amount 7

2.6 Removing the Differential Carrier 8

3 Installing the Air Locker 9

3.1 Mounting the Ring Gear 9

3.2 Installing the Carrier Bearings 10

3.3 Drilling and Tapping the Bulkhead Port 11

3.4 Final Air Locker Assembly 12

3.5 Checking the Backlash 14

3.6 Installing the Seal Housing 15

3.7 Setting up the Bulkhead Fitting 16

3.8 Profiling the Seal Housing Tube 19

3.9 Bench Testing the Air Locker 21

3.10 Reinstalling the Differential & Axles 22

4 Installing the Air System 23

4.1 Mounting the Solenoid 23

4.2 Running & Securing the Air Line 25

4.3 Connection to the Bulkhead Fitting 26

5 Mounting & Connecting the Electrical System 28

5.1 Mounting the Actuator Switch(es) 28

5.2 Wiring the Actuator System 30

6 Testing & Final Assembly 33

6.1 Leak Testing 33

6.2 Testing the Air Locker Actuation 33

6.3 Filling the Differential 34

6.4 Post-Installation Check List 35

7 Parts List 37

7.1 Exploded Assembly Diagram 37

7.2 Itemized Parts List 38

1

2

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  symbols as

you complete each step. It is very important NOT to
miss any of the steps!

3

2 Removing the Existing Differential

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

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

wrenches, Allan keys, and drills.

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

pinion backlash.

 An adjuster-nut wrench. (See your vehicle service manual.)
 A razor knife suitable for cutting nylon tubing.
 A torque wrench. (See your vehicle service manual for the required

torque range.)

 A lubricant drain reservoir.
 A 11.2mm [7/16”] drill and ¼”NPT tap for bulkhead fitting

installation.

 An automotive bearing puller (2 jawed is recommended) or a

differential carrier bearing puller.

 A slide hammer.
 A bearing press or arbor press.

1.2.2 Supplies

 Thread lubricant/sealant compound for pressure fittings

(e.g., LOCTITE #567 Teflon past)

 Thread locking compound (e.g., LOCTITE #272)
 A gasket sealant or replacement gasket for your third member.
 A sufficient volume of differential oil to completely refill your

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

 A soap and water mixture to test for air leaks.
 Differential carrier bearings if required to replace or upgrade to the

50mm Toyota bearing type.

4

2 Removing the Existing Differential

2.1 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.

 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

 Clean around the differential drain plug to prevent dirt from entering

the differential.

 Position a fluid drain reservoir under the differential and loosen the

differential drain plug.

 Completely drain all differential fluid.

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

your oil and in the bottom of the housing which may
indicate a worn bearing or differential component.

2.3 Removal of the Axles and Differential

 Remove the axles according to your vehicle’s service manual.

HINT : When removing the axles try not to damage the paper

gaskets behind the axle flanges.

 Disconnect the drive shaft from the flange of the differential.
 Remove the third member from the differential housing. Refer to

your vehicle’s service manual.

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.

5

2 Removing the Existing Differential

2.4 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.)

 Mark the right hand cap in a similar way.

HINT : Many installers choose to make one punch mark on

the left hand side of the left hand bearing cap and a
similar 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 1.

6

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.

 Set a dial indicator on one of the ring gear teeth. (Fig.2.)

Figure 2.

 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.

 Rotate the differential center 90° and measure again for accuracy.
 Record the average of all measurements.

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2 Removing the Existing Differential

2.6 Removing the differential carrier

 Remove the adjuster nut locking tabs.
 Remove the bearing caps from the third member.
 Remove the adjuster nuts.
 Carefully remove the differential carrier from the third member.
 Remove the tapered roller bearings from the differential carrier with

a bearing puller. (Fig.3.)

HINT : Check the condition of the bearing for wear and

replace if necessary.

Figure 3.

8

3 Installing the Air Locker

3.1 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.

 Thoroughly clean any thread locking compound or other foreign

matter from the holes of the ring gear, the threads of the ring gear
bolts, the mating surfaces of the ring gear and the Air Locker
flange.

HINT : Rubbing the ring gear mounting face with a flat oil

stone before installation will remove any high spots
around the threads.

 Heat the ring gear to between 80 and 100°C (175 - 212°F) in hot

water or in an oven 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.

 Dry the gear and tapped holes with compressed air (if wet).
 Apply a thin film of high-pressure grease to the ring gear shoulder

of the Air Locker to prevent seizing.

 Install the ring gear onto the Air Locker by aligning the tapped holes

and then gently tapping it around in a circle with a soft mallet or
hammer. Avoid using the bolts to pull the ring gear down as this
puts excess strain on the bolts and the differential flange.

 Apply a thread locking compound to the thread of each ring gear

bolt before inserting it. Do not apply locking compound directly into
the threaded hole as this could prevent the bolt from reaching its
full depth.

NOTE : On some models, the crown wheel bolts cannot be

reused and should therefore be replaced. Refer to
your vehicle manufacturer’s service manual for
details.

 Tighten the ring gear bolts in a star pattern with a torque wrench

(Fig.4.) set to your vehicle manufacturer’s specified torque.

9

3 Installing the Air Locker

Figure 4.

3.2 Installing the Carrier Bearings

NOTE : If you are installing an Air Locker into an earlier model

Toyota with a 45mm differential carrier bearing inside
diameter then you will need to use the higher rated
later model 50mm bearings:

Timken # 32010X-32010X
ARB # 160116
If your OE carrier bearings have an ID of 50mm,
replace them with new bearings of the same type.

 Apply a thin film of high pressure grease to the bearing journals of

the Air Locker, then press the bearing cones onto the bearing
journals as shown in Figure 5.

10