ARB RD87 User Manual

RD87

Suzuki Jimny, FR, 8 Bolt RG

INSTALLATION GUIDE

Revision Date 07/11/07

Copyright © 2001 by ARB Corporation Limited

Part No. 210287

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 13

3.6 Installing the Seal Housing 14

3.7 Setting up the Bulkhead Fitting 16

3.8 Profiling the Seal Housing Tube 19

3.9 Bench Testing the Air Locker 20

3.10 Reinstalling the Differential & Axles 21

4 Installing the Air System 22

4.1 Mounting the Solenoid 22

4.2 Running & Securing the Air Line 24

4.3 Connection to the Bulkhead Fitting 25

5 Mounting & Connecting the Electrical System 27

5.1 Mounting the Actuator Switch(es) 27

5.2 Wiring the Actuator System 29

6 Testing & Final Assembly 32

6.1 Leak Testing 32

6.2 Testing the Air Locker Actuation 32

6.3 Filling the Differential 33

6.4 Post-Installation Check List 34

7 Parts List 35

7.1 Exploded Assembly Diagram 35

7.2 Itemized Parts List 36

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, Allan keys, and drills.

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

pinion backlash.

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

torque range.)

c A lubricant drain reservoir.
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 slide hammer.
c A bearing press or arbor press.

1.2.2 Supplies

c Thread lubricant/sealant compound (e.g., LOCTITE #567)
c Thread locking compound (e.g., LOCTITE #272)
c A gasket sealant or replacement gasket for your third member.
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

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

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

the differential.

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

differential drain plug.

c 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

c 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.

c Disconnect the drive shaft from the flange of the differential.
c 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

c 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.)

c 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.

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

Figure 2.

c 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.

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

7

2 Removing the Existing Differential

2.6 Removing the Differential Carrier

c Remove the adjuster nut locking tabs.
c Remove the bearing caps from the third member.
c Remove the adjuster nuts.
c Carefully remove the differential carrier from the third member.
c 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

c Remove the bolts that hold the ring gear in place.
c Using a plastic or copper hammer, tap in a circle around the ring

gear to separate it from the differential carrier.

c 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.

IMPORTANT:

If the Air Locker is being installed in a Japan model Jimny then

the provided ring gear spacer (190103) must be installed between

the ring gear and the Air Locker.

The Japan model Jimny can be identified by measuring the
thickness between the ring gear flange and the bolt face. It

should be 7mm on the Japan model and 4mm otherwise.

c If required place the ring gear spacer (190103) onto the Air Locker.

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

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

c 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.

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

of the Air Locker to prevent seizing.

c 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.

9

3 Installing the Air Locker

c 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.

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

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

Figure 4.

3.2 Installing the Carrier Bearings

c 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.

Figure 5.

10

3 Installing the Air Locker

3.3 Drilling and Tapping the Bulkhead Port

An air line port must be drilled and tapped through the differential
housing to mount the bulkhead fitting into.

c Mark a spot on the right hand side (opposite the ring gear) toward

the top of the differential housing that is in an area well clear of the
differential, the ring gear, and any other obstructions that could
snag the seal housing tube. (Fig.6.)

Figure 6.

c Cover the drive pinion area with a rag to protect it from metal filings.
c Secure the differential housing to the work bench.
c Drill an 11.2mm [7/16”] diameter hole through the differential

housing square to the outside surface. (Fig.7.)

Figure 7.

11

3 Installing the Air Locker

c Tap the hole from the outside using ¼”NPT thread tap.
c Remove any sharp edges that may chip off from around the hole

and fall into the housing.

c Very carefully, remove the rags and inspect with a service light

inside the housing to insure no metal filings are left behind.

3.4 Final Air Locker Assembly

c Clean all parts of the differential assembly making sure the O-ring

grooves are free from any contaminants (e.g., dirt, water, metal
fillings, etc.)

c Place the Air Locker into the differential housing and install the

bearing caps.

NOTE : Be sure to check that the bearing caps are on the

c Insert the bearing cap bolts and hand tighten.

correct sides of the third member and are correctly
aligned.

NOTE : Before attempting to install the adjuster nuts, make

sure the threads on the inside of the bearing caps and
differential housing are perfectly aligned. If they are
not, the threads could be stripped.

c Insert and lightly hand tighten the original adjuster nut into the ring

gear side bearing cap.

NOTE : You should feel no backlash between the ring and

pinion gears once the adjuster nut tightens.

c Reverse the adjuster nut (counterclockwise) ¼ turn.
c Insert the tapped clamping plate behind the adjuster nut supplied

with the Air Locker kit on the opposite side of the differential and
tighten with the appropriate adjuster nut wrench.

NOTE : You should now feel some backlash between the

ring and pinion gears. If not, there might be a
clearance problem which is binding the carrier. Re­check the clearance.

12

3 Installing the Air Locker

3.5 Checking the Backlash

c Set a depth indicator on one of the ring gear teeth (Fig.8.).
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 Refer to your vehicle service manual for the specified maximum

and minimum amounts of backlash.

IMPORTANT:

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 center, increased running

noise, and ultimately, ring and pinion gear damage.

c Adjust the backlash and pre-load using an adjuster nut wrench to

tighten or loosen the adjuster nuts as required. (Refer to your
vehicle service manual.)

c Recheck backlash as before, repeating this procedure until

backlash is within the specified amount.

c Tighten the bearing cap bolts with a torque wrench to the torque

specified in your vehicle manufacturer’s service manual.

Figure 8.

13

3 Installing the Air Locker

3.6 Installing the Seal Housing

c Make sure the grooves in the seal housing and the surface of the

bearing journal are clean and free from any contaminants (e.g.,
water, dirt, metal filings, etc.).

c Generously lubricate the O-rings with oil prior to assembly, then

insert them into the grooves of the seal housing.

NOTE : When assembling the O-rings, be careful not to leave

them twisted when seated in the grooves as this could
cause excessive wear and leakage.

c Install the seal housing by carefully sliding it onto the bearing

journal with a gentle twisting motion. This will allow the O-rings to
engage gently.

c The notch in the seal housing must be lined up with the threaded

hole on the bearing cap to allow the locking tab to be installed
correctly (Fig.9.). Rotate the seal housing accordingly.

Figure 9.

c Using a small screwdriver or hex key, line the threaded holes on

the clamping plate up with one of the internal notches in the
adjuster nut and one of the holes in the seal housing. (Fig.10.)

14

3 Installing the Air Locker

Figure 10.

c Lightly fasten the seal housing to the clamping plate by finger

tightening the supplied cap screws into the clamping plate. Use
thread locking compound on the threads.

c Apply a minimum of 620 kPa [90 PSI] of compressed air to the seal

housing tube and hold the pressure.

c Rotate the differential several times by rotating the drive pinion.

This will allow the seal housing to self center.

c While continuing to slowly rotate the differential with the air system

pressurized, gradually tighten the cap screws in a circular pattern
until fully tightened to 4.6 Nm (3.5 ft.lbs). Do not over tighten.

NOTE : Extreme care must be taken to ensure that the seal

housing is concentric with the bearing journal. Use an
automotive feeler gauge to insure that an even gap is
present all of the way around the seal housing. If the
gap is not even, the seal housing O-rings may leak.
Repeat the cap screw tightening procedure if
necessary.

15

3 Installing the Air Locker

Figure 11.

c Reinstall the locking tabs on both bearing caps (Fig.11.).

3.7 Setting up the Bulkhead Fitting

c Apply thread sealant to the threads of the bulkhead body.
c Screw the bulkhead body into the tapped hole, and tighten.
c Wipe the area clean of any excess thread sealant (inside and

outside of the housing).

c Without using sharp, jagged tools such as pliers (your hands are

the best tool for this job), bend the seal housing tube on the outside
of the housing to approximate the finished profile. This will allow the
tube to be trimmed to a length that would allow it to protrude from
the bulkhead fitting. (See Fig. 12.).

NOTE : Use an automotive brake line tubing cutter to cut the

seal housing tube, never a hacksaw as this will leave
metal filings in the air system.

16

3 Installing the Air Locker

Figure 12.

c From the inside of the housing, insert the trimmed tube into the

bulkhead.

c From the outside of the housing, assemble the small O-ring over

the top of the short length of seal housing tube protruding through
the bulkhead fitting (Fig. 13.).

Figure 13.

c While holding the seal housing tube into the bulkhead fitting, insert

the small drilled end of the center compression nut over the
extended tube as shown in the assembly diagram (Fig.14.), and
screw it into the bulkhead body, and lightly tighten.

NOTE : Be sure to insert the correct end of the center

compression nut into the bulkhead body. The thread
has been partially relieved on the bulkhead side of the
center compression nut to visually identify its
orientation. (Fig.14.)

17

3 Installing the Air Locker

Figure 14.

NOTE : Excessive tightening of the center compression nut is

not necessary to form a good seal around the tube
and may damage the O-ring, 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.

18

3 Installing the Air Locker

3.8 Profiling the Seal Housing Tube

c Without using sharp, jagged tools such as pliers (your hands are

the best tool for this job), bend the seal housing tube so that it
closely follows the profile of the differential. (Figs.15. & 16.)

c Check that the contour of the tube will not interfere with the Air

Locker or the ring gear.

c Support the inner compression nut from rotation with a wrench

(inside the housing) and tighten the center compression nut.

Figure 15.

Figure 16.

19

3 Installing the Air Locker

3.9 Bench Testing the Air Locker

c To test the Air Locker, when 620kPa [90 PSI] shop air is applied to

the seal housing tube, the Air Locker should engage.

c Check all fittings and the seal housing for air leaks.
c Rotate the differential carrier by turning the pinion flange whilst

applying air pressure.

NOTE : An accurate way to test for air leaks is to fit a shut-off

valve to an air pressure gauge, once 620 KPA [90 PSI]
is reached shut the valve off, disconnect the air hose,
and watch to see if there is any drop in pressure, if so,
this will indicate an air leak. (Fig.17.)

Figure 17.

c If a leak is found to be present, spray a soap and water mixture

onto the bulkhead air fitting. Bubbles should appear at any leak
points.

NOTE : Do not spray this soapy mixture inside the differential.

c Check that leaky fittings have been adequately tightened.
c Disassemble, clean threads, and reapply thread sealant if leaking

persists.

c If a leak is found at the seal housing, carefully remove and refit. Be

very careful with the O-rings and check they have not been
damaged during installation.

20

3 Installing the Air Locker

3.10 Reinstalling Differential and Axles

c Replace the paper gasket on the axle housing flange.
c Reinstall the third member to the differential housing according to

your vehicle service manual.

c Reinstall the drive shaft.
c Replace the axle seals if necessary and fit to the axles.
c Insert both axles fully into the housing, engaging splines, and then

gently tap them inward.

NOTE : Be careful not to damage the axle shaft oil seals when

installing the axle. Support the axle’s entire weight
where possible.

c Torque down the axle bolts to manufactures specifications.

21

4 Installing the Air System

4.1 Mounting the Solenoid

4.1.1 Connection to an ARB Air Compressor (Fig.18.)

c Remove one of the 1/8” BSP plugs from its port in the compressor

tank.

c Apply Teflon paste to the nipple (1/8” X 1/8” BSP) and insert it into

the port and tighten.

c Apply Teflon paste to the free end of the nipple.
c Assemble the inlet port side of the solenoid (stamped with a ‘1’)

onto the nipple and hand tighten it. The solenoid should be rotated
into a position that does not obstruct any other ports on the
compressor tank.

NOTE : The solenoid exhausts compressed air through the

center of the black retaining cap when the Air Locker
is disengaged. Make sure this orifice cannot be
obstructed.

c Apply Teflon paste to the threads of the 5mm push-in fitting and

assemble it into the solenoid outlet port (stamped “2”) and tighten.

Figure 18.

ARB

Air Compressor

22

4 Installing the Air System

4.1.2 Connection to an Alternate Air Source

For ease of installation, quality of air supply, and a high level of
dependability from your Air Locker(s), ARB strongly recommends use
of a genuine ARB Air Compressor, however, the Air Locker air system
can be operated on any alternate air source that meets each of the
following guidelines:

c Must supply a minimum of 586 kPa [85 PSI].
c The supply must never exceed 724 kPa [105 PSI].
c The air source should have a tank capacity which enables it to

actuate the Air Locker(s) in one charge so that no hesitation is
experienced when locking one or two differentials.

HINT : A good way to insure that you have the necessary

capacity is to make sure you can engage, disengage,
and then reengage your Air Locker(s) without the air
source having to regenerate (e.g., without the
compressor turning on to refill the tank).

c Must supply clean air, free of rust, dirt, water, or other foreign

matter.

c Must match the 1/8” BSP porting of the Air Locker solenoid.
c Mount solenoid within close proximity of the air supply and secure it

from the effects of vibration and shock.

c Connect the air supply to the 1/8” BSP inlet port of the solenoid

(stamped “1” on the solenoid body) using thread sealant.

IMPORTANT :

ARB cannot warrant your Air Locker(s) against damage caused

as a result of using an alternate air supply. If you have any

doubts as to the suitability of your air system to use in an Air

Locker system, consult your ARB distributor.

23

4 Installing the Air System

4.2 Running and Securing the Air Line

The path taken by the air line from your air source (i.e., compressor) to
your Air Locker is unique to your vehicle and the position of your air
source. Plan ahead carefully when running the air line and always
follow these guidelines:

c Account for axle travel when running the line from the axle to a

fixed point on the vehicle. Leave enough slack in the air line to
allow for maximum suspension travel in both directions.

c Avoid leaving large lengths of air line hanging underneath the

vehicle where they may get tangled on rocks, sticks, etc.

HINT : Cable tying the air line to one of your flexible brake

lines will account for axle travel and should help keep
your line from getting snagged.

c Run the air line all the way from the compressor to the differential

before trimming either end of the line to length. This will save
complications that may arise if the air line has to be removed.

c Make sure the line does not contact sharp edges or abrasive

surfaces that may damage the air line over time.

c Do not run the air line around tight bends that may kink the air line

and restrict or block the air flow.

c Keep the air line well away from your vehicle’s exhaust

components. Air lines will melt if subjected to extreme heat.

c Do not run more air line than necessary. Excess line volume

created when coiling the left over hose, using unusually large
diameter hose, etc., will increase drain on the compressor tank
resulting in the compressor running more often than needed.

c Support the air line by tying it back with cable ties wherever

possible.

c At the solenoid end of the air line, trim the line to length with a

sharp knife.

c To attach the air line to the push-in fitting of the solenoid; insert the

line firmly into the fitting, pull outward on the flange of the fitting
while holding the line as far into the fitting as possible, and then
gently pull outward on the air line to clamp the line in place.

24

4 Installing the Air System

NOTE : To remove the air line from the push-in fitting; pull

outward on the flange of the fitting, push the air line
as far into the fitting as possible and hold, push
inward on the flange, and then pull the air line free of
the fitting.

4.3 Connection to the Bulkhead Fitting

c Trim the air line to length using a sharp knife.
c Insert the support spring over the end of the air line - small end first.

(Fig.19.)

c Insert the outer compression nut over the air line.
c Insert the 5mm [0.197”] ferrule over the end of the air line. Leave

approx. 5mm of tubing between the ferrule and the end of the tube.

Figure 19.

c Insert the support tube all the way into the end of the air line.

25

4 Installing the Air System

HINT : If the support tube is too difficult to insert, place the

end of the air line into a cup of boiled water to soften
the tubing.

c Insert the tube end all the way into the center compression nut.
c Screw on the outer compression nut and tighten. The ferrule and

support tube are now permanently attached.

c Assemble the support spring over the outside of the outer

compression nut.

c Secure any loose sections of tube with a cable tie.

26

5 Mounting & Connecting the Electrical System

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 designed to be difficult to
remove.

For reasons of safety and for ease of operation, the Air Locker
actuator switch(es) should be mounted in a location picked to best suit
the operator. Make sure you have taken the following points into
consideration:

c Switch(es) MUST be mounted and should never be allowed to

simply dangle from the wiring loom during vehicle use.

c Switch(es) should be within easy reach of the driver. Ideally, any

Air Locker switch should be able to be operated without physical
effort or distraction to the driver.

c Switch(es) should be mounted within the line of sight of the driver

so that switch position (‘ON’ or ‘OFF’) can be visually determined
by the rocker position and the illumination state.

c The position of the switch(es) should best eliminate any possibility

of accidental operation by the driver or one of the passengers.

c Switch cutout position(s) must be located in an area with a

minimum of 50mm [2”] of clearance behind the face of the cutout.

c Switch(es) should not be mounted where they will be exposed to

water (e.g., in the lower section of an inner door panel).

c ARB recommends that you apply the Air Locker Warning Sticker

(ARB part # 210101) within close visual proximity of the switch
location.

NOTE : If no adequate position can be found on existing

dashboard panels, a surface mounted bracket (Fig.20.)
may be purchased from your ARB Air Locker
distributor to suit 1, 2, or 3 switches.

27

5 Mounting & Connecting the Electrical System

Figure 20.

28

5 Mounting & Connecting the Electrical System

IDENTIFICATION

UP

5.2 Wiring the Actuator System

5.2.1 Connection to an ARB AIR COMPRESSOR

When wiring the Air Locker actuator switch(es) and solenoid(s) to an
ARB Air Compressor, all connections can easily be set up directly from
the supplied wiring loom. (Fig.21.)

Refer to your ARB Air Compressor Installation Guide for details
on configuring your installation.

ARB AIR COMPRESSOR WIRING LOOM

Figure 21.

SWITCH

TERMINAL

Figure 22.

29

5 Mounting & Connecting the Electrical System

5.2.2 Connection to an Alternate Air Source

When connecting the actuation switch to an alternate air source, the
switch(es) should be wired according to figures 23. and 24. depending
on whether one or two Air Lockers will be installed in the vehicle.

5.2.2.1 Single Air Locker System

c If only one Air Locker is to be installed in the system, the switch and

solenoid should be wired according to figure 23. regardless of
whether the Air Locker has been installed in the front or rear axle of
the vehicle.

c Attach the appropriate switch cover (i.e., ‘FRONT’ or ‘REAR’) to the

switch.

NOTE : Refer to figure 22. for the correct switch terminal

identification and switch orientation.

SINGLE Air Locker SYSTEM

Figure 23.

30

5 Mounting & Connecting the Electrical System

DUAL Air Locker SYSTEM

5.2.2.2 Dual Air Locker System

c If two Air Lockers are to be installed in the system, ARB

recommends that the switches and solenoids be wired according to
figure 24. For safety reasons, this configuration allows SOLENOID
2 to be actuated only if SOLENOID 1 is already on.

c Attach the “REAR AIR LOCKER” switch cover to SWITCH 1, and

the “FRONT AIR LOCKER” switch cover to SWITCH 2.

NOTE : Refer to figure 22. for the correct switch terminal

identification and switch orientation.

c Configure SOLENOID 1 as the air line leading to the rear axle Air

Locker, and SOLENOID 2 as the air line leading to the front axle Air
Locker.

Figure 24.

31

6 Testing & Final Assembly

6.1 Leak Testing

c With the vehicle parked and the engine off, turn the compressor on

and wait until the air system is fully charged.

NOTE : With the Air Locker(s) disengaged, the air 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
compressor tank O-ring seal.

c Actuate the Air Locker(s).
c The compressor should not come on again for a period of at least

15min. Air system recharging within that time period would indicate
that a leak is present in the system.

NOTE : If an alternate air source (e.g., an air cylinder or a belt

driven air pump) is used instead of a compressor, the
air system will have to be leak tested with a pressure
gauge and a shut-off valve in series before the
solenoid input. (Fig.17.)

c 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 should appear at any leak points.

c Check that leaky fittings have been adequately tightened.
c Disassemble, clean threads, and reapply thread sealant if leaking

persists.

6.2 Testing the Air Locker Actuation

To test that your air system, electrical system, and your Air Locker
differential is functioning correctly:

c Support the vehicle such that the wheels are free to rotate (e.g., on

axle stands, a chassis hoist, etc.)

c Leave the parking brake off, the transmission in neutral, and the Air

Locker switch ‘OFF’.

32

6 Testing & Final Assembly

c Turn the ignition to the ‘ON’ position (leaving the motor off). The

large illuminating symbol on the Air Locker switch cover should be
‘OFF’.

c Turn the compressor (or alternate air source) on to charge the air

supply up to its maximum pressure.

c Rotate one wheel by hand.
c 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.

c Turn the Air Locker switch to the ‘ON’ position. The illuminated

symbol on the switch cover should light up.

c Rotate the same wheel again.
c Both wheels should rotate together.
c Turn the switch off again.
c Rotate the same wheel.
c The wheels should again rotate in opposite directions.

6.3 Filling the Differential

NOTE : Consult the ARB Air Locker Operating & Service

Manual for recommendations on differential lubricant
specifications.

c Refill the differential until level with the filler hole.
c Rotate the differential center 2 full turns.
c Check the oil level and add oil if necessary.
c Apply thread sealant to filler plug before inserting.
c Replace the filler plug.
c Clean the differential housing of any oil or grease that may collect

dirt or other abrasive particles.

33

6 Testing & Final Assembly

6.4 Post-Installation Check List

Now that the Air Locker installation has been completed, ARB
recommends that you take the time to complete the following check list
just to insure that you haven’t missed any of the vital steps.

c The air system has been leak tested.
c Thread locking compound was used on the ring gear bolts.
c All torque settings comply with the vehicle manufacturer’s specs

and were set with an accurate torque wrench.

c Differential fluid complies with ARB recommendations and has

been filled to the correct level.

c All air lines and wiring have been securely cable tied to resist

snagging.

c Switch(es) have been securely mounted within operator reach, yet

well away from danger of accidental engagement.

c Switch(es) function properly and illuminate to indicate that Air

Locker(s) are engaged.

c All operators who are to use the Air Locker have read, and fully

understand the ARB Air Locker Operating & Service Manual.

c The Air Locker Warning Sticker has been located within close

proximity of the actuator switch(es).

INSTALLATION PERFORMED BY:

DATE OF INSTALLATION:

___________________________
___________________________

ODOMETER READING:

ARB AIR LOCKER SERIAL No.:

34

___________________________
___________________________

7 Parts List

Suzuki Jimny,

7.1 Exploded Assembly Diagram

(See itemized parts list overleaf)

FR, 8 bolt RG

Figure 25.

35

7 Parts List

7.2 Itemized Parts List

(See exploded diagram figure 25.)

AIR LOCKER MODEL No. : RD87

ITEM # QTY

DESCRIPTION PART #

01 1 FLANGE CAP 023702
02 1 CLUTCH GEAR 050701
03 1 DIFFERENTIAL CASE 012804
04 4 PISTON SPRING 150107
05 3 CROSS SHAFT RETAINING PIN 120403
06 1 LONG CROSS SHAFT 060106
07 2 SHORT CROSS SHAFT 060306
08 1 PISTON 040801
09 1 U-RING 160306
10 1 CYLINDER CAP ASSEMBLY 031303
11 8 CYLINDER CAP RETAINING BOLT 200211
12 8 TAB WASHER – 6mm 150402
13 1 TAPERED ROLLER BEARING

NOT SUPPLIED

14 1 CLAMPING PLATE 090401
15 1 SPLINED SIDE GEAR 131202
16 4 PINION THRUST WASHER 151108
17 4 PINION GEAR 140601
18 1 SPIDER BLOCK 070701
19 1 SIDE GEAR 131102
20 2 SIDE GEAR THRUST WASHER 151008
21 1 ADJUSTER NUT 100601
22 1 SEAL HOUSING 081401
23 2 SEAL HOUSING O-RING 160208
24 3 SEAL HOUSING SCREW 200502

* 1 RING GEAR SPACER 190103
* 1 BULKHEAD KIT, O-RING TYPE, 3.5-5mm 170105
* 1 5mm PUSH-IN FITTING (RI 5 1/8”) 170201
* 1 NIPPLE, 1/8” BSP, MALE TO MALE 170501
* 1 NYLON AIR LINE (5mm Dia X 6m long) 170301
* 1 SOLENOID VALVE 180103
* 1 ON/OFF SWITCH 180209
* 1 SWITCH COVER ‘FRONT’ 180210
* 10 CABLE TIE 180301
* 1 WARNING LABEL 210101
* 1 BUMPER STICKER 210102
* 1 OPERATING & SERVICE MANUAL 210200
* 1 INSTALLATION GUIDE 210287

* Not illustrated in exploded view.

36