ARB AIR LOCKER RD135 User manual

INSTALLATION GUIDE
RD135
Part No. 2102135
Revision Date 21/01/2008
Copyright © 2008 by ARB Corporation Limited
NISSAN H233B, 33 SPL

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 [email protected]
North & South American enquiries [email protected]
Other international enquiries [email protected]
www.arb.com.au

Table of Contents:
1
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 11
3.3 Drilling and Tapping the Bulkhead Port 12
3.4 Final Air Locker Assembly 13
3.5 Checking the Backlash 14
3.6 Installing the Seal Housing 15
3.7 Setting up the Bulkhead Fitting 16
3.8 Profiling the Seal Housing Tube 19
3.9 Bench Testing the Air Locker 21
3.10 Reinstalling the Differential & Axles 22
4 Installing the Air System 23
4.1 Mounting the Solenoid 23
4.2 Running & Securing the Air Line 25
4.3 Connection to the Bulkhead Fitting 26
5 Mounting & Connecting the Electrical System 28
5.1 Mounting the Actuator Switch(es) 28
5.2 Wiring the Actuator System 30
6 Testing & Final Assembly 33
6.1 Leak Testing 33
6.2 Testing the Air Locker Actuation 33
6.3 Filling the Differential 34
6.4 Post-Installation Check List 35
7 Parts List 37
7.1 Exploded Assembly Diagram 37
7.2 Itemized Parts List 38

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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 used in conjunction with your vehicle
manufacturer’s service manual. ARB endeavors to account for every
possible variation in vehicle model when publishing its installation
guides, and guides are updated regularly as new model information
becomes available, however, the rapid and globally varied release of
some vehicles makes it difficult to insure that your vehicle model has
been accurately accounted for. In the case of any technical
discrepancies between this guide and your service manual, we
strongly advise that you adhere to the specifications and techniques
as documented in your service manual.
Although your ARB Air Locker comes complete with all the step by
step instructions you will need to supplement your vehicle
manufacturer’s service manual and install your new differential, ARB
recommends that you have your Air Locker installed by a trained
professional. Many ARB distributors around the world have been fully
instructed in Air Locker installations by ARB, and have gained a wealth
of experience and skill from years of performing similar installations.
Once you begin this installation your vehicle will be immobile until all
steps of the installation are complete. Make sure your Air Locker kit is
the correct model for your vehicle and that it contains all of the parts
listed on back cover of this booklet. Also be sure you have
appropriately equipped yourself with all the necessary tools, parts, and
materials to complete this installation (see Section 1.2 Tool-Kit
Recommendations), and that you have allowed for an appropriate
amount of vehicle down time.
HINT : Place a mark inside each of the symbols as
you complete each step. It is very important NOT to
miss any of the steps!