ARB RD145 User Manual

INSTALLATION GUIDE

RD145

ROCKWELL 2.5T, 16 SPL

Part No. 2102145

Revision Date 17/06/08

Copyright © 2008 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

Pre-Installation Preparation 3

1.1

Tool-Kit Recommendations 4

1.2

2 Removing the Existing Differential 5

Vehicle Support 5

2.1

Differential Fluid Drain 5

2.2

Removing the Axles 6

2.3

Marking the Bearing Caps 6

2.4

Removing the Differential Carrier 7

2.5

3 Installing the Air Locker 8

Re-Mounting the Ring Gear 8

3.1

Assembling the Seal Housing 10

3.2

Installing the Carrier Bearings 11

3.3

Drilling and Tapping the Bulkhead Port 12

3.4

Final Air Locker Assembly 13

3.5

Profiling the Seal Housing Tube 14

3.6

Setting Up the Bulkhead Fitting 15

3.7

Bench Testing the Air Locker 17

3.8

Reinstalling the Differential and Axles 17

3.9

4 Installing the Air System 18

Mounting the Solenoid 18

4.1

Running & Securing the Air Line 20

4.2

Connection to the Bulkhead Fitting 21

4.3

5 Mounting & Connecting the Electrical System 23

Mounting the Actuator Switch(es) 23

5.1

Wiring the Actuator System 24

5.2

6 Testing & Final Assembly 27

Leak Testing 27

6.1

Testing the Air Locker Actuation 28

6.2

Filling the Differential 28

6.3

Post-Installation Check List 29

6.4

7 Parts List 31

Exploded Assembly Diagram 31

7.1

Itemized Parts List 32

7.2

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



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

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

wrenches, Alan keys, and drills.

 A standard automotive feeler gauge.
 A razor knife to cut the nylon tubing.
 An adjuster-nut wrench. (See your vehicle service manual)
 A torque wrench. (See vehicle service manual for 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 bearing press or arbor press.

1.2.2 Supplies

 Thread lubricant/sealant compound for pressure fittings

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

 Thread locking compound (e.g., LOCTITE #272)
 Either a replacement gasket, or gasket sealant, for your differential

cover.

 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.

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

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.

 Clean around the drain plug and differential housing to prevent dirt

from entering the differential.

 Position a fluid drain reservoir under the differential, remove the

drain plug and completely drain all differential oil from the housing.

5

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

installing your Air Locker.

 Remove the wheels, and both axle shafts according to your vehicle

manufacture’s service manual.

NOTE : The axle oil seals are delicate and can be easily

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

 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.

2.4 Marking the Bearing Caps

 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.1.)

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 1.

6

2 Removing the Existing Differential

2.5 Removing the Differential Carrier

 Remove both adjuster nut locking tabs.
 Loosen both bearing caps.
 Using the appropriate adjuster nut wrench, loosen the adjuster nuts

at least half a turn.

 Remove the bearing caps.
 Carefully remove the differential carrier.

NOTE : The differential carrier is heavy and quite difficult to

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

7

3 Installing the Air Locker

3.1 Re-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 two halves of the original differential
carrier.

 Cut the cable ties holding the two halves of the Air Locker together

and separate the case and flange cap.

 Apply a thin film of high pressure grease to the outside diameter on

the case of the Air Locker to prevent seizing.

 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 between the ring gear and the Air
Locker flange.

 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 bolt holes with compressed air (if wet).
 Install the ring gear onto the case of the Air Locker by aligning the

bolt holes and then gently tapping it around in a circle with a soft
mallet (Figure 2.).

Figure 2.

8

3 Installing the Air Locker

 Apply a thin film of high pressure grease to the ring gear diameter

of the flange cap and install the flange cap into the ring gear.

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

bolt before inserting into the Air Locker.

 Install the nuts and tighten the ring gear bolts in a star pattern with

a torque wrench according to your vehicle manufacturer’s specified
torque (Figure 3.). The nuts will be held captive by the machined
face on the case (Figure 4.).

Figure 3.

Figure 4.

9