ARB AIRLOCKER RD196 User manual

RD196
NISSAN C200K, 31 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 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
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
Disconnecting the Axles
7
2.4
Marking the Bearing Caps
8
2.5
Checking the Current Backlash Amount
9
2.6
Removing the Differential Center
10
3 Bench Measurement
13
3.1
Approximate Backlash Shimming
13
3.2
Calculation & Selection of Shims
15
4 Installing the Air Locker
16
4.1
Insuring Adequate Oil Drainage
16
4.2
Installing the Carrier Bearings
17
4.3
Mounting the Ring Gear
18
4.4
Drilling and Tapping the Bulkhead Port
19
4.5
Assembling the Seal Housing
21
4.6
Pre-Load Shimming
22
4.7
Modifying the Bearing Cap
24
4.8
Reinstalling the Bearing Caps
26
4.9
Checking the Backlash
27
4.10
Setting Up the Bulkhead Fitting
28
4.11
Profiling the Seal Housing Tube
30
4.12
Bench Testing the Air Locker
31
4.13
Modifying the IFS Assembly
32
5 Installing the Air System
34
5.1
Mounting the Solenoid
34
5.2
Running & Securing the Air Line
36
5.3
Connection to the Bulkhead Fitting
37
6 Mounting & Connecting the Electrical System
39
6.1
Mounting the Actuator Switch(es)
39
6.2
Wiring the Actuator System
40
7 Testing & Final Assembly
44
7.1
Leak Testing
44
7.2
Reinstalling the Axles
44
7.3
Testing the Air Locker Actuation
45
7.4
Re-Sealing & Filling the Differential
45
7.5
Post-Installation Check List
46
8 Parts List
47
8.1
Exploded Assembly Diagram
47
8.2
Specifications
47
8.3
Itemized Parts List
48

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.
(not required on aluminum housings)
 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 3.3)
 A 11.2mm [7/16”] drill and ¼” NPT tap for bulkhead fitting
installation.
 An automotive bearing puller (2 jawed is recommended) or a
differential carrier bearing puller.
 A bearing press or arbor press.
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.
 Teflon paste.
 Replacement oil seal from Nissan for the long axle tube.

1 Introduction
5
1.3 Assembly Type Identification
IMPORTANT:
Sections 2 and 3 of this installation guide have been written to
accommodate two different Nissan C200K applications:
A the Independent Front Suspension (IFS) type.
(Refer to Fig.1.)
B the live axle Salisbury type.
(Refer to Fig.2.)
To eliminate confusion, you should identify which figure your vehicle
matches with. The section numbers within the guide that refer ONLY
to the IFS type have been suffixed with an ‘ A ’, and those that refer
ONLY to the live axle type have been suffixed with a ‘ B ’.
PLEASE IGNORE ALL SECTIONS WHICH
DO NOT APPLY TO YOUR APPLICATION
Figure 1.
Figure 2.
A
B

2 Removing the Existing Differential
6
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.
2.2.1 A IFS Fluid Drain
 Remove any skid plates covering the bottom of the front axle area
and position a fluid drain reservoir under the differential.
 Remove the threaded drain plug and completely drain all differential
oil from the housing.
 Finger-tighten the drain plug back in to prevent drips during the
removal of the axle assembly.
2.2.2 B Live Axle Fluid Drain
 Clean any loose dirt from around the differential cover flange area,
the filler plug area, and the drain plug (if any) to avoid
contaminating the differential cavity with abrasive particles.
 Position a fluid drain reservoir under the differential.
 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
7
2.3 Disconnecting the Axles
2.3.1 A IFS CV Shafts
 Remove the wheels, brakes and CV shafts according to your
vehicle manufacturer’s service manual.
NOTE : The oil seals are delicate and can be easily damaged.
Support the weight of the CV shaft when drawing them
out of their sockets in the housing.
 Disconnect the drive shaft from the differential drive flange.
 Completely remove the differential assembly from the vehicle.
 Secure the differential assembly to a work bench.
 Remove the front access cover plate.
2.3.2 B Live Axle
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 Removing the Existing Differential
8
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.3.)
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 3.

2 Removing the Existing Differential
9
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 4.
Figure 4.
 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
10
2.6 Removing the Differential Center
IMPORTANT:
YOU MUST SPREAD THE HOUSING ON CAST IRON MODELS
Spreading the differential housing with a differential case
spreader is a step which is critical to set up bearing pre-load on
cast iron differential housings. 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.
2.6.1 A IFS Diff Removal
 Remove the oil seal at the end of the long axle tube (Fig. 5.).
NOTE : A new oil seal MUST be obtained from Nissan before
the diff is re-assembled.
Figure 5.
 Remove the circlip that holds the long axle shaft in place, and
remove the long axle shaft from the housing.
 Remove both bearing caps.
 Carefully spread the housing (Fig.6.) 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.
OIL SEAL

2 Removing the Existing Differential
11
 Once the housing has been adequately spread, the differential may
be removed by pulling forward on the differential carrier.
NOTE : The differential center is heavy and quite difficult to
handle when covered in oil. Take care not to drop it.
 Relieve any tension on the spreader immediately after the
differential has been removed.

2 Removing the Existing Differential
12
2.3.2 B Live Axle
 Remove both bearing caps.
 Carefully spread the housing (Fig.6.) 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 6.
NOTE : The differential center is heavy and quite difficult to
handle when covered in oil. Take care not to drop it.
 Relieve any tension on the spreader immediately after the
differential has been removed.

3 Bench Measurement
13
3.1 Approximate Backlash Shimming
In order to reproduce a similar pre-load and ring and pinion backlash
in your Air Locker to that of your original differential, measurements
need to be taken so that a shim thickness can be calculated.
 Secure the original differential to a work bench.
 Remove the bolts that hold the ring gear in place.
 Using a plastic or copper hammer, tap in a circle around the ring
gear to separate it from the differential carrier.
 Remove the original bearings and shims from the differential center
using a bearing puller.
NOTE : Keep the bearings and shims separated so that they
can be identified as to which end of the differential
they came from.
 Examine the bearing cups and cones from Figure 7. for damage or
wear and, if necessary, discard them and replace with the same
size and type of bearings.
Figure 7.

3 Bench Measurement
14
 Using 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 Fig.7.) and record this
measurement as ‘A’.
 Measure the thickness of the factory shim removed from the end of
the differential carrier (shown as ‘B’ in Fig.7.) and record this
measurement as ‘B’.
Figure 8.
 Measure the distance from the Air Locker bearing shoulder to the
ring gear mounting face (shown as ‘C’ in Fig.8.) and record this
measurement as ‘C’.

3 Bench Measurement
15
3.2 Calculation & Selection of Shims
Ideally, the measurement you recorded as ‘C’ from the Air Locker
differential will closely match ‘A’ on the existing differential (within
0.1mm [0.004”] ) and then the factory shim can be reused, however,
quite often these measurements will vary slightly between one factory
differential and the next.
If this is the case you must create a new shim pack thickness by using
the measurements you recorded earlier to find a desired measurement
for ‘D’ in Figure 8.
Use the following calculation:
A + B –C = D (Replacement Shim Pack)
HINT : If your calculations are correct then the following
equation will also be true:
A + B –C –D = ZERO
 Create a shim pack to match the thickness calculated as ‘D’.
To achieve the desired shim thickness you can:
• Machine down the factory shim thickness.
• Add shims between the factory shim and the bearing cup.
HINT : A selection of shims of this size have been supplied
with your Air Locker kit.
• Purchase new factory shims at the desired thickness.
• Use a universal shim kit available from most drive train
specialists.
• Add small amounts of shim between the bearing cone and the
bearing seat.
NOTE : NEVER machine the Air Locker.

4 Installing the Air Locker
16
4.1 B Insuring Adequate Oil Drainage
IMPORTANT:
Some Salisbury axles were manufactured with poor oil drainage
between the axle tubes and the differential housing. This can
often result in one of the axle tubes filling up with differential oil
while running. In most cases this will result in a blocked air vent
which will cause the differential housing to pressurize and expel
oil from the axle seals at the wheels or force oil into the air
system of the Air Locker, eventually expelling oil at the solenoid
valve. This is a design flaw which was corrected by most
automakers in the later releases of their axle assemblies. If no
lower drainage point is present in the differential housing then it
is critical that you modify the housing to include one.
 Inspect the differential housing for the presence of adequate
drainage in both axle tubes (refer to Fig.9.).
Figure 9.
 If drainage exists but is inadequate then a slot or hole should be cut
into the housing on the lower side of the tube(s) to allow oil out of
the axle tube area.

4 Installing the Air Locker
17
NOTE : Make sure any grinding dust, filings or drill chips left
behind by cutting the drainage slots is completely
cleaned out of the housing.
 Check that the axle air vents are clear and working correctly.
4.2 Installing the Carrier Bearings
 Apply a thin film of high pressure grease to both bearing journals of
the Air Locker to prevent seizing.
 Using a bearing press or arbor press, press one of the bearing
cones (supplied with the Air Locker kit) onto one bearing journal of
the Air Locker (refer to Figure 10.) until the bearing seats firmly
against the bearing journal shoulder.
Figure 10.
 Invert the Air Locker and press the other tapered roller bearing
cone onto the opposite bearing journal of the differential carrier until
the bearing seats firmly against the bearing journal shoulder.
NOTE : Do not add any shims between the bearings and the
bearing seat. Shimming of the Air Locker will be
performed with the supplied shim kits and/or the
original master shims (if any) on the outside of the
carrier bearings.

4 Installing the Air Locker
18
4.3 Mounting the Ring Gear
 Apply a thin film of high pressure grease to the ring gear shoulder
of the Air Locker to prevent seizing.
 Thoroughly clean any thread locking compound or other foreign
matter from the holes of the ring gear, the threads of the ring gear
bolts, and the mating surfaces between the ring gear and the Air
Locker flange.
HINT : Stoning the ring gear mounting face before
installation will remove any high spots around the
threads.
 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.
 Dry the gear and bolt holes with compressed air (if wet).
 Install the ring gear onto the Air Locker by aligning the bolt holes
and then gently tapping it around in a circle with a soft mallet.
Avoid using the bolts to pull down the ring gear as this puts excess
strain on the bolts and the differential flange.
 Apply a thread locking compound to the thread of each ring gear
bolt before inserting it. Do not apply threading compound directly
into the threaded hole as this could prevent the bolt from reaching
its full depth.
 Tighten the ring gear bolts in a star pattern with a torque wrench
according to your vehicle manufacturer’s specified torque.