Page 1
RD197
AAM 925 & 950
Part No. 2102197
INSTALLATION GUIDE
Revision Date 20/01/2012
Copyright © 2012 by ARB Corporation Limited
Page 2
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: +61 (3) 9761 6622
Kilsyth, Victoria Fax: +61 (3) 9761 6807
AUSTRALIA
3137
Australian enquiries sales@arb.com.au
North and South American enquiries sales@arbusa.com
Other international enquiries exports@arb.com.au
www.arb.com.au
Page 3
Table of Contents:
1
1 Introduction
3
1.1
Pre-Installation Preparation
3
1.2
Tool-Kit Recommendations
4
1.3
Assembly Type Identification
5
2 Removing the Existing Differential
6
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
8
2.6
Removing the Differential Center
11
3 Installing the Air Locker
12
3.1
Re-Mounting the Ring Gear
12
3.2
Drilling and Tapping the Bulkhead Port
13
3.3
Profiling the Seal Housing Tube (A)
15
3.4
Assembling the Seal Housing
17
3.5
Installing the Carrier Bearings
19
3.6
Final Air Locker Assembly
20
3.7
Profiling the Seal Housing Tube (B)
22
3.8
Checking the Backlash
23
3.9
Setting Up the Bulkhead Fitting
23
3.10
Reinstalling Differential and Axles
25
4 Installing the Air System
26
4.1
Mounting the Solenoid
26
4.2
Running & Securing the Air Line
28
4.3
Connection to the Bulkhead Fitting
29
5 Mounting & Connecting the Electrical System
31
5.1
Mounting the Actuator Switch(es)
31
5.2
Wiring the Actuator System
32
6 Testing & Final Assembly
36
6.1
Leak Testing
36
6.2
Testing the Air Locker Actuation
37
6.3
Re-Sealing & Filling the Differential
37
6.4
Post-Installation Check List
38
7 Parts List
39
7.1
Exploded Assembly Diagram
39
7.2
Itemized Parts List
40
Page 4
2
Page 5
1 Introduction
3
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 use d i n conjunction with your vehicle
manufacturer’s service manual. ARB endeavors to account for every
possible variation in vehicle model when publ ishing its installation
guides, and guides are updated regularl y as new model informati on
becomes available, however, the rapid and globally varied release of
some vehicles makes it difficult to insure that your vehicle model has
been accurately account ed for. In the case of any technical
discrepancies between this guide and your service manual, we
strongly advise that you adhere to the spe cif i cations and techniq ues
as documented in your se rvice 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 different ial , ARB
recommends that you have your Air Locker installed by a trained
professional. Many ARB distributors around the world have been ful ly
instructed in Air Locker installations by ARB, and have gained a wealth
of experience and skill from years of performi ng similar install at i ons.
Once you begin this installation your vehicle will be immobile until all
steps of the instal lation are complete. Make sure your Air Lo ck er kit is
the correct model fo r your vehicle and that i t contains all of the parts
listed on back cover of this booklet. Also be s ure 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 allow ed for an appropriate
amount of vehicle dow n 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!
Page 6
1 Introduction
4
1.2 Tool-Kit Recommendations
Below is a list of tool s and supplies you may need to complete t his
installation. Requirements for your vehicle may vary. Pl ease con sult
your vehicle service manual for additiona l rec ommendations.
1.2.1 Tools
Standard aut omotive sizes (metric and/or imperial) of sockets,
wrenches, Alan keys, and drills.
A dial indicator or other suitable measuring tool for c hecking ring &
pinion backlash.
An adjuster-nut wrench. (See your vehicle service man ual .)
A razor knife to cut the nylon tubing.
A torque wrench. (See vehicle se rvice manual for requi red torque
range.)
A lubricant drain reservoir.
A 11.2mm [7/16”] drill and ¼” NPT tap for bulkhead fitt i ng
installation.
An automotiv e bearing puller (e.g., ARB Bearing Puller #07 70001)
or a differential carrier bearing puller.
A bearing press or arbor press.
Automotiv e brake line tubing cutt er.
A soft hammer (e.g., Copper/Rawhide/Nylon).
1.2.2 Supplies
Thread lubric ant/sealant compound fo r pressu re fitti ngs
(e.g., LOCTITE #567 Teflon paste)
Thread locki ng compound (e.g., LOCTITE #272)
Either a repl acement gasket, or gasket sealant, for your differential
cover.
A sufficient volume of differential oil to completely refill your
housing. (see the ARB A i r Locker Operating and Service Manual
for recommended lubricants)
A soap and wat er mixture to test for air leaks.
Page 7
1 Introduction
5
A
B
1.3 Assembly Type Identification
IMPORTANT:
Sections 2 and 3 of this installation guide have been written to
accommodate two different application installations:
A the Independent Front Suspension (IFS) t ype with an
aluminum clamshell housing (Refer to Fig.
1.)
B the live axle Salisb ury type with a cast iron housing.
(Refer to Fig.2.)
To eliminate confusi on, you should identi fy which figure your vehicle
matches with. The section numbers wit hi n the guide that refer O NLY
to the IFS type have been suffixed with an ‘ A ’, and those that refer
ONLY to the live axle type have been suf fixed with a ‘ B ’.
PLEASE IGNORE ALL SECTIONS WHICH
DO NOT APPLY TO YOUR APPLICATION
Figure 1.
Figure 2.
Page 8
2 Removing the Existing Differential
6
2.1 Vehicle Support
Safely secure t he vehicle on a hoi st . We recommend support i ng
the vehicle on a chassis hoist to keep the dif ferential area at a
convenient working height and to leave t he wheels and axles free
to be rotated and removed.
Once supported off the ground, rele as e t he 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 me tal 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
Remove any skid plates covering the bottom of the front axle area
and position a fluid drain reservoir under the di fferential.
Remove the threaded drain plug and completely drain all di fferential
oil from the housing.
Finger-tighten the drain plug bac k in to prevent drips duri ng the
removal of the ax l e asse mbl y.
2.2.2 B Live Axle Fluid Drain
Clean around the differential cover plate seal to prevent dirt from
entering the differen tial.
Position a fluid drain reservoir under the differential a nd loosen all
differential cover plate retaining bolts.
Gently pry the cover plate away from the differential ho using to
completely drain all differential fluid.
Once draine d, remove the differential cover plate.
HINT : It would be a good idea to drill and tap for a tap ered oil
drain plug to assist with future oil changes.
Page 9
2 Removing the Existing Differential
7
2.3 Disconnecting the Axles
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.
2.3.1 A IFS CV Shafts
Remove the st ub axles from the diffe rential housing according to
your vehicle manufa ct urer’s service manual.
Disconnect t he drive shaft from the pinion flange.
Completely remove the different i al assembly from the vehicle.
2.3.2 B Live Axle 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
installing your Air Locker.
Remove the wheels, and brakes a ccording to your v ehi cle
manufacturer’s service manual.
Unbolt the fou r bolts retaining the hub and withdraw the axle shafts.
Page 10
2 Removing the Existing Differential
8
2. 4 B Marking the Bearing Caps
Using a pointed center punch, gent l y 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.
HINT : Many installers choose to make on e punch mark on
the left hand side of the left han d bearing cap and one
similar punch mark on the hou si ng at close proximity to
the cap mark. The right hand sid e i s then designated
with two punch marks on the right hand side of the cap
and two similar punch marks on the housing.
Figure 3.
3.)
2.5 Checking the Current Backlash Amount
IMPORTANT:
This step is a precautionary m easure recommended by ARB due
to the fact that some after market ring and pinion sets have bee n
manufactured to run with di ff erent backlash setting s than those
specified by your vehicle man ufacturer. Although ARB must
recommend you set backlash according to your service manual
guidelines, we also advise that you compare the backlash
measurements tak en 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 man ual or your local authorized
ARB installer for more information.
Page 11
2 Removing the Existing Differential
9
2.5.1 A Backlash Measurement of IFS Clamshell
NOTE : Because access to the r i n g gear is difficult i n the
clamshell housing, the following alternative method
for measuring backlash has been provided.
Firmly clamp the differential housing in a vice or to a workbench.
Set up a depth indicator with a magnet base on the vice or ben ch
and position the indi cator tip on the machine d f l at of the pinion yoke
as shown in figure
Remove the breather to allow a ham mer handle or other suitable
device to be jammed against the ring gear teeth t o prevent the
differential center from rotating. (Fig.
Figure 4.
4.
4.)
Page 12
2 Removing the Existing Differential
10
With the hamm er handle preventin g the differential fro m rotating,
rotate the pinion y oke in both directions while observing the
maximum variation in depth from the ind icat or (i.e., the highest
value minus the lowest value). This value w il l be comparable to the
ring and pinion back lash and provide an ac cu rat e method for
setting up the backlash once the Air Locker is installed.
Rotate the dif f erential center 90° and measure again for ac curacy.
Record the average of all measurements.
2.5.2 B Backlash Measurement of Live Axle
Set a depth indicator on one of the ring gear teeth as in Figure 5.
Figure 5.
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 ind icat or (i.e., the highest
value minus the lowest value). This value is referred to as the ring
and pinion backlash.
Rotate the dif fer enti al center 90° and measure again for a c curacy.
Record the average of all measurements.
Page 13
2 Removing the Existing Differential
11
2.6 Removing the Differential Center
2.6.1 A IFS Clamshell Differential Center Removal
Remove all bolts from around the o utside of the clam shell.
Gently pry the clamshell apart a nd remove the differential center.
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 Live Axle Differential Center Removal
Remove both adjuster nut locking t abs.
Loosen both bearing caps.
Loosen the adj uster nuts enough to remove the differential center.
Remove the bearing caps and tapered roller bearing cups.
HINT : Be sure not to mix up the bearing cups. Later it will be
necessary to match the bearing cups to their cones.
Carefully remove the differenti al center.
NOTE : The differential center is heavy and quite difficult to
handle when covered in oil. Take care not to drop it.
Page 14
3 Installing the Air Locker
12
3.1 Re-Mounting the Ring Gear
Remove the bol ts t hat hold the ring gear i n pl ace.
NOTE : AAM 925 & 950 ring gear bolts are usually left hand
threaded.
Using a plasti c or copper hammer, t ap i n a circle around the ring
gear to separate it f rom the original differential carrier.
Apply a thi n f i l m of high-pressure grease t o the ring gear shoulder
of the Air Locker to prevent seizing.
Thoroughly clean any thread locking c ompound or other foreign
matter from the holes of t he ring gear, the thread s of t he ring gear
bolts, and the mating su rf aces between the ring ge ar and the Air
Locker flange.
HINT : Stoning the ring gear mounting f a ce bef ore
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 sli ghtly expand the gear and facilitate
assembly.
NOTE : NEVER HEAT GEARS WITH A FLAME! This could
damage the hardened surfa c e of t he gea r a nd re sult
in premature wear or failur e.
Dry the gear a nd bolt holes with com pressed air (if wet).
Install the ring gear onto the Air Locker by aligning the bolt holes
and then gently t apping i t around in a circle with a soft mallet.
Avoid using the bolt s t o pull down the ring gear as t his 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 t hreading compound directl y
into the threaded hole as this could prevent t he bolt from reaching
its full depth.
Tighten the ri ng gear bolts in a star pat tern with a torque w rench
according to your v ehicle manufacturer’s specified torque.
Page 15
3 Installing the Air Locker
13
3.2 Drilling and Tapping the Bulkhead Port
An airline port must be drilled and tapped through the differential
housing to mount th e bulkhead fitting int o.
3.2.1 A Port Location on the IFS Clamshell Housing
Figure 6.
On the non-pi nion side of the clamsh el l, cover the bearing area wi t h
a rag to protect from m etal filings.
Drill through the housing square to t he outside surface using a
11.2mm [7/16”] drill in the position shown in Fi gure
6.
NOTE : When viewed from i nsi de the housing the bulkhead
Tap the hole from the outside using a ¼” NPT pipe tap.
Remove any sharp edges from the hole that may chip-off and fall
port position must be as sho wn in Figure 7.
into the housing.
Carefully remove the rags and inspect with a service light inside the
housing to insure no drill filings are left behind.
Figure 7.
Page 16
3 Installing the Air Locker
14
3.2.2 B Port Location on the Live Axle Housing
Mark a spot on the top of the outsi de shell of the different ial
housing as shown in Figure
Figure 8.
8.
Cover the drive pinion and axle t ube areas with a rag to protect
them from metal filings.
Drill through the housing square to t he outside surface using a
11.2mm [7/16”] drill.
Tap the hole from the outside using a ¼” NPT pipe tap.
Remove any sharp edges from the hole that may chip-off and fal l
into the housing.
Carefully remove the rags and inspect with a service light inside the
housing to insure no metal filings are left behi nd.
Page 17
3 Installing the Air Locker
15
3.3 A Profiling the Seal Housing Tube
The seal housing tube needs to be bent into a profile that will allow it
to clear the Air Locker and the differential housing, and ex i t through
the bulkhead port.
Bend the tube to the profile shown i n Figures 9. & 10.
Figure 9.
Figure 10.
Page 18
3 Installing the Air Locker
16
Figure 11.
Trial fit the seal housing to the clamsh ell as shown in Figure 9.
Mark the tube a pproximately 8-10mm out from the edge of th e
housing (Figure
Remove the seal housing from the differential housin g and trim the
tube to length.
11.).
NOTE : Figure 10. shows a housi ng that has been saw-cut in
half. This has been done for ill ustration purposes so
that the seal housing tube profil e and seal housing
bracket can be seen in position.
Page 19
3 Installing the Air Locker
17
3.4 Assembling the Seal Housing
3.4.1 A IFS Clamshell Seal Housing Assembly
Figure 12.
Make sure the grooves and airway of the seal housing ar e clean
and free from any cont am inants (e.g. water, dirt, metal filings, etc.).
Inspect the s eal housing O-rings (suppl ied) for dirt, damage or
other conditions which might cause leaks.
Generously lubricate the O-ring s w i t h oil prior to assembly, then
insert them into the grooves of the seal hou sing.
NOTE : When assembli ng the O-rings, be careful not to leave
them twisted when seated in the grooves as this could
Lubricate the seal housing runnin g surface on the Air Locker carrier
cause excessive wear and leakag e.
with oil.
Assemble the seal housing retai ni ng bracket onto the s hort spigot
of the seal housing, so t hat it will be held captive between the
flange cap and seal housing (as shown i n F ig. 6).
Carefully inst al l t he seal housing and retaini ng bra cket by sliding
them all of the way ont o t he bearing journal with a gentle twisting
motion. This will all ow the O-rings to engage ge ntly.
Page 20
3 Installing the Air Locker
18
3.4.2 B Live Axle Seal Housing Assembly
Figure 13.
Make sure the grooves and airway of the seal housing ar e clean
and free from any cont am inants (e.g. water, dirt, metal filings, etc.).
Inspect the s eal housing O-rings (suppl ied) for dirt, damage or
other conditions which might cause lea ks.
Generously lubricate the O-ring s w i t h oil prior to assembly, then
insert them into the grooves of the seal hou sing.
NOTE : When assembli ng the O-rings, be careful not to leave
them twisted when seated in the groov es as this could
Lubricate the seal housing runnin g surface on the Air Locker carrier
with oil.
Carefully inst al l t he seal housing by sliding it all of the way ont o the
bearing journal with a gentle twisting mo t i on. Thi s w i l l all ow the Orings to engage gent ly.
cause excessive wear and leakage.
NOTE : Make sure the o rientation of the seal housing is as
shown in Figure 13., with the seal housing flange
closest to the flan ge cap.
Page 21
3 Installing the Air Locker
19
3.5 Installing the Carrier Bearings
If the tapered roller bearings from the original different ial carrier are
to be reused, then remove them with an automot i ve bearing puller
and inspect them for damage and/or wear and replace them if
necessary.
Apply a thi n f i l m of hi gh-pressure grease to both bearing journal s of
the Air Locker to prevent seizing.
Using a bearing press or arbor pres s, press one of the bearing
cones onto one bea ring journal of the Air Locker (refer to figure
until the bearing seats firmly against the bearing journal shoulder.
14.)
Figure 14.
Invert the A ir Locker and press the other tapered roller bearing
cone onto the opposite bearing journal of t he differential carrier u ntil
the bearing seats firmly against the bearing journal shoulder.
Page 22
3 Installing the Air Locker
20
10mm
3.6 Final Air Locker Assembly
3.6.1 A Assembly into IFS Clamshell Housing
Place the Air Locker on a bench with the seal housing si de on top.
Assemble the non-pini on side of the clamsh ell onto the Air Locker
ensuring that the se al housing tube goes through the bulkhead
fitting, and that the seal housing bracket lines up with the rib s in the
clamshell (Figure
NOTE : Image shown is of a housing that h as been saw-cut in
half. This has been done for ill ustration purposes so
that the seal housing tube profil e and seal housing
bracket can be seen in position.
15.)
Figure 15.
Turn the diff and housing over and a ssemble the pinion side of the
clamshell making sure you apply an appropriat e gasket or sealant
between the two halves of the clamshell.
Tighten all of the bolts to the torque specified in y our vehicle
service manual. Make sure that both adjust er nuts are hand tight.
Page 23
3 Installing the Air Locker
21
3.6.2 B Assembly into Live Axle
Reinstall the Air Locker into the axle housin g.
Leaving the b ol ts out at this stage, install the bearing caps
orientated as they were marked before they were removed.
Rotate the seal housing so that the slot is pointing straight out of
the axle opening. Then install the supplied seal housing bracket
with the tab locating in the seal housing slot as shown in Figure
16.
Figure 16.
Insert the bearing cap bolts and finger tighten. It is not necessary to
torque them down a t t hi s t i me.
Using the appropriate adjuster nut wrench, lightly hand tighten the
seal housing side adjuster nut.
NOTE : You should feel no backlash between the ring and
Reverse the adj uster nut (counter clockwise) ¼ turn.
Using the adj uster nut wrench, hand ti ghten the opposite a djuster
nut.
NOTE : You should now feel som e backlash between the ring
pinion gears once the adjuster n ut tightens.
and pinion gears.
Page 24
3 Installing the Air Locker
22
3.7 B Profiling the Seal Housing Tube
Without using sharp jagged tools such as pliers (your hands are the
best tool for this job) gently bend the sea l housing tube in a shape
that will clear the differential and housing, and exit through the
bulkhead port as shown in Figure
Trim the tube to length using an aut om otive brake line tube cutter.
NOTE : Never use a hac ksaw to cut the seal ho using tube as
this will leave metal filings in the air system.
Figure 17.
Figure 18.
17.
Page 25
3 Installing the Air Locker
23
Gently bend the seal housing tube into a profile that pr ot rudes
through the bulkhead port and doesn’t pull at al l on the seal
housing. (see Fig.
NOTE : Ensure there is clearance between the seal housing
tube, Air Locker, seal housing bracket and cover plate.
3.8 Checking the Backlash
Set up a depth indicator and measure t he backlash as detailed in
section 2.5.1 or 2.5.2.
Refer to your vehicle service manu al f or the specified maxim um
and minimum amount s of backlash.
It is critical to set up bearing pre-load when a differential is
installed. Improper pre-load will result in undue bearing wear,
increased stresses in the differential carrier, increased running
noise and ultimately, ri ng and pi ni on gear damage.
18.)
IMPORTANT :
Adjust the ba cklash and pre-load usi ng an adjuster nut wrench to
tighten or loosen the adj uster nuts as required. (Refer to your
vehicle service man ual . )
Recheck backla sh as before, repeating this procedu re until
backlash is within the specified amount.
Reinstall the adjuster nut locking tabs.
A On the “Cl amshell” replace the b reather.
B On the “Live Axle” tighten all bearing cap bolts with a t orque
wrench to the torque specified in your vehicle manufacture r’s
service manual.
3.9 Setting Up the Bulkhead Fitting
Apply thread sealant to the threads of the bulkhead body.
Place the bulkhead body over t he short length of tube protruding
from the housing an d screw it into the tapped hole, and tighten.
Wipe the are a clean of any excess thr ead sealant (inside and
outside of the housing).
From the out side of the housing, assemble the small O-ring over
the top of the short l ength of seal housin g protruding through t he
bulkhead fitting.
Page 26
3 Installing the Air Locker
24
While holding the seal housing tub e into the bulkhead fi t ting, insert
the small drilled end of the center compression nut over the
extended tube as shown in the assembly diagram (Fig.
screw it into the bulk head body, and light l y tighten.
Figure 19.
19.), and
NOTE : Excessive tighteni ng of t he center compression nut is
not necessary to form a good seal a round the tube
and may damage the O-ri ng, the seal housing tube, or
the threads of the compression nut.
NOTE : Make sure the seal housing tube is all of the way into
the center compression nut while you are tightening
it.
Page 27
3 Installing the Air Locker
25
3.10 Reinstalling Differential and Axles
3.10.1 A Reinstalling IFS Housing
Reinstall the differential housing into the vehicle.
Reconnect the drive shaft to the pi nion flange.
Reassemble the stub axles and re m ai ning components a cc ording
to your vehicle manufacturer’s service manual.
3.10.2 B Reinstalling Axles
Reinstall the axles and torque down th e axle bolts according to the
manufacturer’s specification.
Reassemble the remainder of the differential assembly
(e.g., hubs, brakes, wheels, etc.) to the vehicle according to your
vehicle’s service ma nual.
NOTE : Be care ful not to damage the axle oil seals with the
spline of the axle.
Page 28
4 Installing the Air System
26
4.1 Mounting the Solenoid
4.1.1
Connection to an ARB Air Compressor (Fig.20.)
Remove one of the 1/8” BSP plugs from its port in the compressor
tank.
Apply Tef lon paste to the nipple (1/ 8” X 1/8” BSP) and insert it into
the port and tighten.
Apply Tefl on paste to the free end of t he nipple.
Assemble the inlet port side of the solenoid (stamped with a ‘1’)
onto the nipple and ti ght en. The solenoid should be rotated into a
position that does not obstruct any other ports on the compresso r
tank.
NOTE : The solenoi d exhausts compressed ai r through the
center of the black retaining cap when the Air Locker
is disengaged. Make sure this orifice cannot be
obstructed.
Apply Tefl on paste to the threads of the 5mm push-in fitting and
assemble it into the solenoid outlet port (stamped “2”) and tig ht en.
ARB
Air Compressor
Figure 20.
Page 29
4 Installing the Air System
27
4.1.2 Connection to an Alternate Air Source
For ease of installati on, quality of air supply, and a high level of
dependability from your
of a genuine ARB Air Co mpressor, however, the
can be operated on any alternate air sourc e that meets each of t he
following guidelines:
Must supply a minimum of 85PSI [58 6kPa].
The Air source should have a tank ca pacity that enables it t o
actuate the Air Locker(s) in one charge so that no hesitation
is experienced whe n l oc king one or two differentials.
HINT : A good way to insure that you have the necessary
capacity is to mak e sure you can engage, d i sengage,
and then reengage your Air Loc ker(s) withou t the air
source having to regenerate (e.g., without the
compressor turning on to refill the tank).
Must supply clean air, free of rust, dirt, water, or other foreign
matter.
Air Locker(s), ARB stron gl y recommends use
Air Locker air system
Must match t he 1/8” BSP porting of t he Air Locker solenoid.
Mount solenoid within close pr oximity of the air supply and secure it
from the effects of vibration and shock.
Connect the ai r supply to the 1/8” BS P i nl et port of the solenoid
(stamped “1” on the solenoid body) usin g t hread sealant.
IMPORTANT :
ARB cannot warrant your Air Locker(s) against dam ag e caused
as a result of using an alternate ai r supply. If you have any
doubts as to the suitability of your air system to use in an Air
Locker system, consult y our ARB distributor.
Page 30
4 Installing the Air System
28
4.2 Running and Securi ng the Air Li ne
The path taken by the air line from your air s ource (i.e., compres sor) to
your
source. Plan ahead ca ref ul ly when running the ai r l ine and always
follow these guidelines:
HINT : Cable tying the air line to one of your flexible brake
Air Locker is unique to your vehicle and the position of your air
Account for axle travel when run ni ng the line from the ax le t o a
fixed point on the vehi cle. Leave enough slack in the air line to
allow for maximum suspension travel in both directions.
(Not necessary on I FS installations)
Avoid leaving large lengths of air li ne hanging underneat h the
vehicle where they m ay get tangled on ro ck s, sticks, etc.
lines will account for axle trav el and should help keep
your line from getting snagged.
Run the air line all the way from the co mpressor to the differe ntial
before trimming either end of the line to lengt h. This will save
complications that m ay arise if the air line ha s t o be removed.
Make sure the l ine does not contact s harp edges or abrasive
surfaces that may damage the air line over time.
Do not run the air line around tight b ends which may kink the air
line and restrict or bl ock the air flow.
Keep the air lin e well away from your vehicle’s exhaust
components. Air lines will melt if subjected to extreme heat.
Do not run more air line than neces sary. Excess line volum e
created when coiling the left over hose, using unusually l arge
diameter hose, etc., will increase drain on the compressor tank
resulting in the compre ssor running more of ten than needed.
Support the air line by tying it back w ith cable ties wherev er
possible.
At the solenoid end of the air line, alw ays trim the line to length with
a sharp knife to avoid di storting the tube wher e i t plugs into the
push-in fitting.
NOTE : To remove the air line from the push-in fitting; while
holding the flange of the fitting out, push the air line
into the fitting as far as possibl e, the n press the flange
inward, then pull the air line free of the fitting.
Page 31
4 Installing the Air System
29
To attach the air line to the push-in fit ting of the solenoid; i nsert the
line firmly into the fitting, pull outward on the flange of the fitt i ng
while holding the line as f ar into the fitting as possible, and then
gently pull outward on the air line to clamp t he li ne in place.
4.3 Connection to the Bulkhead Fitting
In the case of an IFS axle assembly or in the case that the a xle
assembly has been com pletely removed from the vehicle, the
assembly will have to be remounted in orde r t o position the
bulkhead fitting in its correct location f or air line access.
Trim the air lin e t o length using a sharp knife.
Insert the support spring over the end of the air line - small end first.
(Fig.
21.)
Insert the outer compression nut over the air line.
Push the airli ne onto the barb on that c enter compression nut,
ensuring that it is pushed all the way to the en d.
Figure 21.
HINT : If the tube is too difficult to push on, place the e nd of
the air line into a cup of boiled water to soften the
tubing.
Page 32
4 Installing the Air System
30
Screw on the outer compression nut and tighten, while supporting
the center compression nut with a 3/8” spanner. The airline is now
attached to the center compression nut.
NOTE : The outer compression nut will ti ghten against a stop.
Over tightening wil l not create a better seal.
Assemble the support spring over the outside of the outer
compression nut.
Secure any l oose sections of tube wi t h a cable tie.
Page 33
5 Mounting & Connecting the Electrical System
31
5.1 Mounting the Actuator Switch(es)
Air Locker actuator switch(es) can be easily panel mounted inside the
vehicle in a 21mm x 36. 5mm [0.83” x 1.44”] rectangular cutout.
NOTE : Only attach the cover plate to the face of the switch
once the switch has been mounted and wired correctly
as the cover plates are designe d to be difficult to
remove.
For reasons of safety and for ease of operation, t he Air Locker
actuator switch(es ) should be mounted in a location picked to be st suit
the operator. Make su re you have taken the following points into
consideration:
Switch(es) MUST be mounted and should never be allow ed to
simply dangle from the wiring loom during vehicle use.
Switch(es) s hould be within easy reac h of the driver. Ideally , any
Air Locker switch should be abl e to be operated without physical
effort or distraction to the driver.
Switch(es) s hould be mounted within the line of sight of the driver
so that switch position (‘ON’ or ‘OFF’) c an be visually determ ined
by the rocker position and the illumination stat e.
The position of t he switch(es) shoul d best eliminate any possibility
of accidental operation by the driver or one of t he passengers.
Switch cutout position(s) must be located in an area wi t h a
minimum of 50mm [2”] of clearan ce behind the face of the cutout.
Switch(es) s hould not be mounted where they will be exposed to
water (e.g., in the lower section of an inner door panel).
ARB recomm ends that you apply the Air Locker Warning Sticker
(ARB part # 210101) within close visual proximity of the switch
location.
NOTE : If no adequate positi on can be found on existing
dashboard panels, a surface m ounted bracket
(Fig.
22.) may be purchased from your ARB Air Locker
distributor to suit 1, 2, or 3 s witches.
Page 34
5 Mounting & Connecting the Electrical System
32
Figure 22.
5.2 Wiring the Actuator System
5.2.1 Connection to an ARB Air Compressor
When wiring the Air Lock er actuator switch (es) and solenoid(s) to an
ARB Air Compressor, all connections can easily be set up di rectly from
the supplied wiring loom. (Fig.23.)
NOTE : 180409 model loom shown for reference only. Refer to
your ARB Air Compressor Installation Guide for
details on configuring y our installation.
Page 35
5 Mounting & Connecting the Electrical System
33
SWITCH
IDENTIFICATION
Figure 23.
TERMINAL
Figure 24.
UP
Page 36
5 Mounting & Connecting the Electrical System
34
5.2.2 Connection to an Alternate Air Source
When connecting the actuation switch t o an alternate air source, the
switch(es) should b e wired according to f i gure s 25. and 26., depending
on whether one or two Air Lockers will be i nstalled in the vehicle.
5.2.2.1 Single Air Locker System
If only one Air Locker is to be installed in the system, t he sw i tch and
solenoid should be wi red according to figure
whether the Air Locker has been installed in the front or rear axle of
the vehicle.
Attach the appropriate switch cover (i.e., ‘FRONT’ or ‘REAR’) to
the switch.
NOTE : Refer to Figure 24. for the correct switch terminal
identification and switch orientation.
SINGLE Air Locker SYSTEM
Figure 25.
25. regardless of
Page 37
5 Mounting & Connecting the Electrical System
35
DUAL Air Locker SYSTEM
5.2.2.2 Dual Air Locker System
If two Air Lockers are t o be i nstalled in the syst em, ARB
recommends that the switches and solenoids be wired according to
figure
2 to be actuated onl y if SOLENOID 1 is already on.
Attach the “REAR AIR LOCKER” sw itch cover to SWITCH 1, and
the “FRONT AIR LOCKER” switch cover t o SWITCH 2.
NOTE : Refer to Figure 24. for the correct switch terminal
Configure SOLENOID 1 as the air li ne leading to the rear axle Air
Locker, and SOLENOID 2 as the air line leading t o the front axle Air
Locker.
26. For safety reasons, this configuration allows SOLENOID
identification and switch orientation.
Figure 26.
Page 38
6 Testing & Final Assembly
36
6.1 Leak Testing
With the vehicle parked and the engi ne off, turn the compressor on
and wait until the air system is fully charged.
NOTE : With the Air Locker(s ) disengaged, the ai r source (i.e.,
compressor) should not have to recharge over time.
Intermittent recharging without Air Locker use usually
indicates a leak at the solenoid fittings or at the
Actuate the Air Locker(s).
The compressor should not come on agai n for a period of at least
15min. Air system rec harging within that time period would indicat e
that a leak is present i n the system.
NOTE : If an alternate air s ource (e.g., an air cylinder or a bel t
If a leak is found to be present, spray a soap and water mixture
onto all air fittings in the system while the compressor is fully
charged. Bubbles s hould appear at any leak poi nts.
compressor tank O-ring seal.
driven air pump) is used inste ad of a compressor, the
air system will have to be leak tested with a pressure
gauge and a shut-off valve i n ser i es before the
solenoid input.
Check that le aky fittings have been adequately tightene d.
Disassemble, clean threads, and reapply thread sealant i f leaking
persists.
Page 39
6 Testing & Final Assembly
37
6.2 Testing the Air Locker Actuation
To test that your air system, electrical sy st em , and your Air Locker
differential is functioning correctly:
Support the vehicle such that t he wheels are free to rotate (e.g., on
axle stands, a chas s i s hoist, etc.)
Leave the parking brake off, the t rans m ission in neutral, a nd the Air
Locker switch ‘OFF’.
Turn the ignit i on to the ‘ON’ positio n (leaving the motor off ). The
large illuminating symbol on the Air Locker switch cover should be
‘OFF’.
Turn the com pressor (or alternat e air source) on to charge the ai r
supply up to its max im um pressure.
While supporting the drive shaft f l ange, rotate one wheel by hand.
The wheel should rotate freely and the opposite wheel should be
turning in the opposite direction without any resistance or
mechanical noise from within the differential.
Turn the Air Locker switch to the ‘ON’ position. The illuminat ed
symbol on the switch cover should light up.
Rotate the sam e wheel again.
Both wheels should rotat e togeth er.
Turn the switch off again.
Rotate the sam e wheel.
The wheels s hould again rotate in opposite directions.
6.3 Re-Sealing & Filling the Differential
NOTE : Consult the ARB Air Locker Operating & Service
Manual for recommendation s on differential lubricant
B On the “Live Axle” replace the differential cover using g asket
specifications.
sealant or a new differe ntial cover gasket for your make of vehicle.
Refill the differential until level with the filler hole.
Rotate the dif f erential center 2 ful l t urns.
Check the oil l evel and add oil if necessary.
Replace filler plug (apply thread sealant to fill er plug before
inserting if it is a threaded type plug).
Wipe differential housing clean of any oil or grease which may
collect dirt or other abrasive particles.
Page 40
6 Testing & Final Assembly
38
6.4 Post-Installation Check List
Now that the Air Locker installation has been completed, ARB
recommends that you take the time to com pl et e the following che c k li st
just to insure that you haven’t missed any of the vital steps.
The air system has been leak tested.
Thread locki ng compound was used on the ring gear bolts.
All torque set tings comply with the vehicle manufacturer’s specs
and were set with an accurate torque wrench.
Differential f l uid complies with A RB recommendation s and has
been filled to the correct level.
All air lines and wiring have been securely cable tied to resist
snagging.
Switch(es) have been securely mounted within operator reach, yet
well away from danger of accidental engag em ent.
Switch(es) f unction properly and il l umi nate to indicate that Air
Locker(s) are engag ed.
All operators who are to use the Air Locker have read, and fully
understand the ARB A i r Locker Operating & Service Manual.
The Air Locker Warning Sticker has been located within close
proximity of the actu at or switch(es).
INSTALLATION PERFORMED BY:
DATE OF INSTALLATION:
ODOMETER READING:
ARB AIR LOCKER SERIAL No:
___________________________
___________________________
___________________________
___________________________
Page 41
7 Parts List
39
7.1 Exploded Assembly Diagram
(See itemized parts list overleaf)
Figure 27.
Page 42
7 Parts List
40
AIR LOCKER MODEL No. : RD197
01
1
FLANGE CAP ASSEMBLY
028612
02
1
BONDED SEAL
160703
03
1
CLUTCH GEAR
050807
04
1
LONG CROSS SHAFT
061501
05
1
SHORT CROSS SHAFT
061601
06
2
SIDE GEAR THRUST WASHER
151007
07
1
DIFFERENTIAL CASE
013212
08
2
RETAINING PIN
120601
09
2
COUNTERSUNK SCREW
200214
10
2
TAPERED ROLLER BEARING
11
1
SEAL HOUSING ASSEMBLY
080903
12
2
SEAL HOUSING O-RING
160239
13
12
RETURN SPRING
150107
14
1
SPLINED SIDE GEAR
728K131**
15
1
SPIDER BLOCK
070404
16
4
PINION GEAR
728K131**
17
4
PINION THRUST WASHER
151113
18
1
SIDE GEAR
728K131**
*
1
SEAL HOUSING BRACKET (LIVE AXLE)
220203
*
1
SEAL HOUSING BRACKET (IFS)
220211
*
1
BULKHEAD KIT,O-RING TYPE,3.5-5mm
170111
*
1
PUSH-IN FITTING (5mm to 1/8”BSPP)
170201
*
1
AIR LINE (5mm DIA X 6m LONG)
170301
*
1
NIPPLE (1/8” to 1/8” BSPT)
170501
*
1
SOLENOID VALVE (12V)
180103
*
1
SWITCH
180209
*
1
SWITCH COVER (FRONT)
180210
*
1
SWITCH COVER (REAR)
180211
*
10
CABLE TIE
180301
*
1
WARNING LABEL
210101
*
1
BUMPER STICKER
210102
*
1
OPERATING & SERVICE MANUAL
210200
*
1
INSTALLATION GUIDE
2102197
7.2 Itemized Parts List
(See exploded diagram fig ure 27.)
ITEM # QTY DESCRIPTION PART #
NOT SUPPLIED
* Not illustrated in exploded view.
** Available only as complete 6 gear set
Loading...