ARB AIRLOCKER RD170 User manual

RD170
DANA 70/80, 32 SPLINE,
LOW SPEED
AIR OPERATED
LOCKING DIFFERENTIAL
INSTALLATION GUIDE

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: [phone]
Kilsyth, Victoria Fax: [phone]
AUSTRALIA
3137
Australian enquiries [email protected]
North and 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
Disconnecting the Axles
6
2.4
Marking the Bearing Caps
6
2.5
Checking the Current Backlash Amount
7
2.6
Removing the Differential Center
8
3 Installing the Air Locker
10
3.1
Insuring Adequate Oil Drainage
10
3.2
Approximate Backlash Shimming
11
3.3
Mounting the Ring Gear
15
3.4
Drilling and Tapping the Bulkhead Port
16
3.5
Assembling the Seal Housing
17
3.6
Pre-Load Shimming
18
3.7
Reinstalling the Bearing Caps
19
3.8
Checking the Backlash
20
3.9
Setting Up the Bulkhead Fitting
21
3.10
Bench Testing the Air Locker
23
4 Installing the Air System
24
4.1
Mounting the Solenoid
24
4.2
Running & Securing the Air Line
26
4.3
Connection to the Bulkhead Fitting
27
5 Mounting & Connecting the Electrical System
29
5.1
Mounting the Actuator Switch(es)
29
5.2
Wiring the Actuator System
30
6 Testing & Final Assembly
34
6.1
Leak Testing
34
6.2
Reinstalling the Axles
34
6.3
Testing the Air Locker Actuation
35
6.4
Re-Sealing & Filling the Differential
35
6.5
Post-Installation Check List
36
7 Parts List
37
7.1
Exploded Assembly Diagram
37
7.2
Specifications
37
7.3
Itemized Parts List
38

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, Alan keys, and drills.
A dial indicator or other suitable measuring tool for checking ring &
pinion backlash.
A standard automotive feeler gauge.
A razor knife to cut the nylon tubing.
A differential housing spreader, to facilitate removal of the carrier.
(e.g., ARB Differential Spreader #0770003)
A torque wrench. (See vehicle service manual for required torque
range.)
A lubricant drain reservoir.
Suitable measuring tools to measure a differential for pre-load
and/or backlash shimming. (See Section 3.2)
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 bearing press or arbor press.
A soft hammer (e.g., copper/rawhide/nylon).
1.2.2 Supplies
Thread lubricant/sealant compound for pressure fittings
(e.g., LOCTITE #567 Teflon paste)
Thread locking compound (e.g., LOCTITE #272)
Either a replacement gasket, or gasket sealant, for your differential
cover.
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
HINT : This is a good time to check for metal particles in
your oil, on your drain plug, or in the bottom of the
housing which may indicate a worn bearing or
differential component.
Clean around the differential cover plate seal to prevent dirt from
entering the differential.
Position a fluid drain reservoir under the differential and loosen all
differential cover plate retaining bolts.
If a drain plug exists, remove it and completely drain all differential
oil from the housing.
If no drain plug exists then the oil can be drained by loosening the
cover bolts and gently prying the cover away at the bottom until oil
runs out.
HINT : If a drain plug does not exist then it would be a good
idea to drill and tap for a tapered oil drain plug to assist
with future oil changes.
Once drained, remove the differential cover plate.

2 Removing the Existing Differential
6
2.3 Disconnecting the Axles
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 according to your vehicle
manufacturer’s service manual.
Remove both axle shafts according to your vehicle manufacturer’s
service manual.
NOTE : The axle oil seals are delicate and can be easily
damaged. Support the weight of the axle shaft when
drawing them out of their sockets in the housing.
2.4 Marking the Bearing Caps
Using a 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.)
HINT : Many installers choose to make one punch mark on
the left hand side of the left hand bearing cap and one
similar punch 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 depth indicator on one of the ring gear teeth as in figure 2.
Figure
2.
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.
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 Center
IMPORTANT:
YOU MUST SPREAD THE HOUSING
Spreading the differential housing with a differential case
spreader is a step which is critical to set up bearing pre-load
(See Figure 3.). 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.
Remove both bearing caps.
Carefully spread the housing (Fig.3.) enough to remove the
differential center. (Refer to your vehicle’s service manual).
NOTE : Do not spread the housing more than 0.50mm [0.020”].
HINT : Be sure not to mix up the left and right hand bearing
cups. Later it will be necessary to know which cup
came from which side.
Once the housing has been adequately spread, the differential may
be removed by pulling forward on the differential carrier.
Figure
3.