ARB Air Locker RD204 User manual

RD204
SUZUKI, VITARA/SIDEKICK,
10 BOLT, REAR, 26 SPLINE
AIR OPERATED
LOCKING DIFFERENTIAL
INSTALLATION GUIDE

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 & Differential
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
15
3.8
Profiling the Seal Housing Tube
18
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
26
5.1
Mounting the Actuator Switch(es)
26
5.2
Wiring the Actuator System
27
6 Testing & Final Assembly
30
6.1
Leak Testing
30
6.2
Testing the Air Locker Actuation
30
6.3
Filling the Differential
31
6.4
Post-Installation Check List
32
7 Parts List
33
7.1
Exploded Assembly Diagram
33
7.2
Specifications
33
7.3
Itemized Parts List
34

2

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 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!

1 Introduction
4
1.2 Tool-Kit Recommendations
Below is a list of tools and supplies you may need to complete this
installation. Requirements for your vehicle may vary. Please consult
your vehicle service manual for additional recommendations.
1.2.1 Tools
Standard automotive sizes (metric and/or imperial) of sockets,
wrenches, Allan keys, and drills.
A dial indicator or other suitable measuring tool for checking ring &
pinion backlash.
An adjuster-nut wrench. (e.g. ARB Adjuster Nut Pliers #0770002)
An automotive brake tubing cutter to cut the steel tubing.
A razor knife suitable for cutting nylon tubing.
A torque wrench. (See vehicle manual for required torque range.)
A lubricant drain reservoir.
An 11.2mm [7/16”] drill and ¼”NPT tap for bulkhead fitting
installation.
An automotive bearing puller (e.g. ARB Bearing Puller #0770001)
or a differential carrier bearing puller.
A slide hammer.
A bearing press or arbor press.
1.2.2 Supplies
Thread lubricant/sealant compound for pressure fittings (e.g.,
LOCTITE #567 or Teflon Paste)
Thread locking compound (e.g., LOCTITE #272)
A gasket sealant or replacement gasket for your third member.
A sufficient volume of differential oil to completely refill your
housing. (See the ARB Air Locker Operating and Service Manual
for recommended lubricants)
A soap and water mixture to test for air leaks.

2 Removing the Existing Differential
5
2.1 Vehicle Support
Safely secure the vehicle on a hoist. We recommend supporting the
vehicle on a chassis hoist to keep the differential area at a
convenient working height and to leave the wheels and axles free
to be rotated and removed.
Once supported off the ground, release the parking brake and
leave the vehicle in neutral. Chock the wheels if necessary.
2.2 Differential Fluid Drain
Clean around the differential drain plug to prevent dirt from entering
the differential.
Position a fluid drain reservoir under the differential and loosen the
differential drain plug.
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 Removing the Axles and Differential
Remove the axles according to your vehicle’s service manual.
HINT : You may need a slide hammer for this exercise as the
wheel bearings are a tight fit inside the axle housing.
Take extra precaution and try not to damage the paper
gaskets behind the axle flanges.
Disconnect the drive shaft from the flange of the differential.
Remove the third member from the differential housing. Refer to
your vehicle’s service manual.
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.

2 Removing the Existing Differential
6
2.4 Marking the Bearing Caps
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.)
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.

2 Removing the Existing Differential
7
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.
Set a dial indicator on one of the ring gear teeth. (Fig.2.)
Figure
2.
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.
Rotate the differential center 90and measure again for accuracy.
Record the average of all measurements.

2 Removing the Existing Differential
8
2.6 Removing the Differential Carrier
Remove the adjuster nut locking tabs.
Remove the bearing caps from the third member.
Remove the adjuster nuts.
Carefully remove the differential carrier from the third member.
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.