ARB RD101 User manual

RD101
DANA 30, 27 SPLINE,
3.54 & DOWN
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 [e-mail]
North and South American enquiries [e-mail]
Other international enquiries [e-mail]
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 Installing the Air Locker
12
3.1
Insuring Adequate Oil Drainage
12
3.2
Installing the Carrier Bearings
13
3.3
Approximate Backlash Shimming
14
3.4
Mounting the Ring Gear
16
3.5
Drilling and Tapping the Bulkhead Port
17
3.6
Assembling the Seal Housing
19
3.7
Pre-Load Shimming
20
3.8
Reinstalling the Bearing Caps
25
3.9
Checking the Backlash
26
3.10
Setting Up the Bulkhead Fitting
27
3.11
Profiling the Seal Housing Tube
29
4 Installing the Air System
30
4.1
Mounting the Solenoid
30
4.2
Running & Securing the Air Line
32
4.3
Connection to the Bulkhead Fitting
33
5 Mounting & Connecting the Electrical System
35
5.1
Mounting the Actuator Switch(es)
35
5.2
Wiring the Actuator System
36
6 Testing & Final Assembly
40
6.1
Leak Testing
40
6.2
Reinstalling the Axles
40
6.3
Testing the Air Locker Actuation
41
6.4
Re-Sealing & Filling the Differential
41
6.5
Post-Installation Check List
42
7 Parts List
43
7.1
Exploded Assembly Diagram
43
7.2
Itemized Parts List
44

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.

1 Introduction
5
1.3 Assembly Type Identification
IMPORTANT:
Sections 2 and 3 of this installation guide have been written to
accommodate two different Dana 30 applications:
Athe Independent Front Suspension (IFS) type with an
aluminum housing (Refer to Fig.1.)
B the live axle Salisbury type with a cast iron 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 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 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.

Gently pry the cover plate away from the differential housing to
completely drain all differential fluid.

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, and brakes according to your vehicle
manufacturer’s service manual.

Disconnect the drive shaft from the differential drive flange.

Disconnect the struts (shocks) from the lower control arms.

Remove the forked strut mounts off of the bottoms of the strut
cylinders.

Disconnect the upper and lower ball joints.

Tap the CV shafts outward to disconnect the retaining clips, and
draw the knuckle joints outward until you can completely disengage
the spline of the CV shafts from the differential housing.
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.

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 CV Shafts
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.

Disconnect the drive shaft from the differential drive flange.

Disconnect the upper and lower ball joints.

Draw the knuckle joints outward until you can completely disengage
the spline of the CV shafts from the differential housing.
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.

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.