ARB RD90 User Manual

INSTALLATION GUIDE

RD90

TOYOYA 7.5”, IFS

Part No. 210290

Revision 06/07/05

Copyright © 2002 by ARB Corporation Limited

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
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	Removing the Differential Assembly	6
2.4	Checking the Current Backlash Amount	8
2.5	Removing the Differential Center	10

3 Installing the Air Locker		11
3.1	Approximate Backlash Shimming	11
3.2	Calculation & Selection of Backlash Shims	13
3.3	Mounting the Ring Gear	14
3.4	Installing the Carrier Bearings	15
3.5	Preload Shim Measurement	16
3.6	Calculation & Selection of Preload Shims	18
3.7	Drilling & Tapping the Bulkhead Port	19
3.8	Installing the Bulkhead Fitting	21
3.9	Installing the Differential Center	21
3.10	Setting Up the Bulkhead Fitting	24
3.11	Final Assembly	25
3.12	Checking the Backlash	27
3.13	Bench Testing the Air Locker	30
3.14	Reinstalling the Differential Assembly	31

4 Installing the Air System		32
4.1	Mounting the Solenoid	32
4.2	Running & Securing the Air Line	34
4.3	Connection to the Bulkhead Fitting	35

	5	Mounting & Connecting the Electrical System		36
		5.1	Mounting the Actuator Switch(es)	36
		5.2	Wiring the Actuator System	37
	6	Testing & Final Assembly		40
		6.1	Leak Testing	40
		6.2	Testing the Air Locker Actuation	40
		6.3	Re-Sealing & Filling the Differential	41
		6.4	Note For ADD Equipped Vehicles	41
		6.5	Post-Installation Check List	42
	7	Parts List		43
		7.1	Exploded Assembly Diagram	43
		7.2	Itemized Parts List	44
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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!

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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

cStandard automotive sizes (metric and/or imperial) of sockets, wrenches, Allan keys, and drills.

cA dial indicator or other suitable measuring tool for checking ring & pinion backlash.

NOTE : Split ‘clamshell’ type Toyota differential housings require a long series dial indicator to check backlash. Refer to Section 1.3 Vehicle Type Identification.

cA razor knife for nylon tubing.

cA torque wrench (See vehicle service manual for required torque range)

cA lubricant drain reservoir.

cA slide hammer for removing CV axles.

cSuitable measuring tools to measure a differential for preload shimming. (e.g., an automotive feeler gauge)

cA 11.2mm [7/16”] drill and ¼”NPT tap for bulkhead fitting installation.

cAn automotive bearing puller (2 jawed) or a differential carrier bearing puller.

cA bearing press or arbor press.

1.2.2 Supplies

cThread lubricant/sealant compound (e.g., LOCTITE #567)

cThread locking compound (e.g., LOCTITE #272)

cA gasket sealant or replacement gasket for your differential.

cA sufficient volume of differential oil to completely refill your housing. (see the ARB Air Locker Operating and Service Manual for recommended lubricants)

cA soap and water mixture to test for air leaks.

cTeflon paste.

cA selection of differential bearing shims to set-up preload and backlash.

4

1 Introduction

1.3 Assembly Type Identification

IMPORTANT:

Sections 2 and 3 of this installation guide have been written to accommodate two different styles of Toyota IFS differential housings:

Athe front accessed type with bearing caps (Refer to Fig.1.)

Bthe ‘clamshell’ type split housing (Refer to Fig.2.)

To eliminate confusion, you should identify which figure your vehicle matches with. The section numbers within the guide that refer to the front accessed type have been suffixed with an ‘ A ’, and those that refer to the ‘clamshell’ type have been suffixed with a ‘ B ’.

PLEASE IGNORE ALL SECTIONS WHICH DO NOT APPLY TO YOUR APPLICATION

A

Figure 1.

B

Figure 2.

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2 Removing the Existing Differential

2.1 A B Vehicle Support

cSafely 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.

cOnce supported in the air, chock the wheels (if necessary) and leave the vehicle in neutral.

2.2 A B Differential Fluid Drain

cPosition a fluid drain reservoir under the differential.

cRemove the drain plug and drain all of the oil from the housing.

HINT : This is a good time to check for metal particles in your oil and on the end of the magnetic drain plug which may indicate a worn bearing or differential component.

c Once drained, reinstall the drain plug.

2.3 A B Removing the Differential Assembly

cRemove the stub axles from the differential housing according to your vehicle manufacturer’s service manual.

NOTE : Rubber oil seals can be easily damaged. Support the weight of the axle when extracting it across the edges of the seals.

HINT :

HINT :

Some Toyota IFS axles can be removed easier by disconnecting the upper ball joint.

Toyota IFS axle stubs are retained with a snap ring which is considered to be a one-use part. Keep two of these clips on-hand in case the clip(s) are damaged or sheared off while removing the stub axle. Make sure all of the remains of the clips are accounted for so that they cannot damage differential components and seals.

cDisconnect the drive shaft from the pinion flange.

cCompletely remove the entire differential assembly.

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2 Removing the Existing Differential

2.3.1 A Marking the Bearing Caps

cSecure the differential assembly to a work bench.

cCompletely remove the front access cover.

cUsing a small pointed center punch, gently mark the left bearing cap in a way which will enable you to know which cap is ‘LEFT’ and ‘RIGHT’, and which way is ‘UP’ and ‘DOWN’. (Fig.3.)

cMark the right hand cap in a similar way.

Figure 3.

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.

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2 Removing the Existing Differential

2.4 A B Checking the Current Backlash Amount

IMPORTANT:

This step is a precautionary measure recommended by ARB due to the fact that some aftermarket 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.

2.4.1 A Backlash for Front Access Housing

cSet a plunge type dial indicator on one of the ring gear teeth as in Figure 4.

Figure 4.

cWhile 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.

cRotate the differential center 90° and measure again for accuracy.

cRecord the average of all measurements.

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2 Removing the Existing Differential

2.4.2 B Backlash for Clamshell Housing

cSet a long series lever type dial indicator on one of the ring gear teeth. Access to the ring gear teeth is gained through the oil filler hole. (Refer to Figure 5.)

Figure 5.

cInsert a large flat screwdriver or pry-bar through one of the axle stub holes so that it wedges between the cross shaft and the carrier body so that the differential center can be rotated by the cross shaft, and not by the spline of one of the differential gears.

cWhile supporting the pinion gear by holding the drive shaft flange, rotate the differential in both directions (with the screwdriver or prybar) 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.

cRotate the differential center 90° and measure again for accuracy.

cRecord the average of all measurements.

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2 Removing the Existing Differential

2.5 A B Removing the Differential Center

cRemove the floating shaft (or ADD unit if present) from the side of the differential housing.

NOTE : The floating shaft or stub axle is retained by the same type of clip that was used to retain the outer stub axle. A slide hammer may be required for safe removal.

Refer to your vehicle manufacturer’s service manual.

2.5.1 A Front Access Housing Disassembly

cRemove the bearing cap retaining bolts and then remove both bearing caps.

cGently pry the differential center forward until it comes free of the housing.

NOTE : Be sure not to mix up the left and right hand tapered roller bearing cups or preload shims. Later it will be necessary to know which cup came from which bearing and which shim came from which side of the differential.

2.5.2 B Clamshell Housing Disassembly

cRemove all bolts from around the outside of the clamshell.

cGently pry the clamshell apart and remove the differential center.

cUsing an arbor press, remove both bearing cups and preload shims by pressing the face of the shims through the housing from the outside.

NOTE : Be sure not to mix up the left and right hand tapered roller bearing cups or preload shims. Later it will be necessary to know which cup came from which bearing and which shim came from which side of the differential.

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3 Installing the Air Locker

3.1 A B Approximate Backlash Shimming

In order to reproduce a similar preload and ring and pinion backlash in your Air Locker to that of your existing differential, measurements need to be taken so that a shim thickness can be calculated.

cSecure the differential to a work bench.

cRemove the bolts that hold the ring gear in place.

NOTE : Ring gear bolt locking tabs used on some models will not be required on the Air Locker and may be discarded.

cUsing a plastic or copper hammer, tap in a circle around the ring gear to separate it from the differential carrier.

cRemove the original bearings from the differential center using a bearing puller.

NOTE : Keep the bearings separated so that they can be identified as to which end of the differential they came from.

cExamine the bearing cup and cone from Figure 6. for damage or wear and, if necessary, discard it and replace it with the same size and type of bearing.

FACTORY DIFFERENTIAL

Figure 6.

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3 Installing the Air Locker

cUsing a caliper or similarly accurate measurement method

(i.e., able to take accurate measurements within 0.04mm [0.0015”]), measure the distance from the shoulder of the bearing journal to the ring gear mounting face (shown as ‘A’ in Figure 6.) and record this measurement as ‘A’.

cMeasure the thickness of the factory shim removed from the end of the differential carrier (shown as ‘B’ in Figure 6.).and record this measurement as ‘B’.

AIR LOCKER DIFFERENTIAL

RING GEAR

FLANGE

Figure 7.

cMeasure the distance from the Air Locker bearing shoulder to the ring gear mounting face (shown as ‘C’ in Figure 7.) and record this measurement as ‘C’.

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