ARB® Air Locker™ Locking Differential, Rear H233B
Contents
1. ARB n LULnRER AIR OPERATED LOCKING DIFFERENTIALS INSTALLATION GUIDE NISSAN H233B 31 SPL Part No 2102136 Revision Date 19 03 2008 Copyright 2008 by ARB Corporation Limited 1 Introduction 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 131 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 Locker2. B 3 3 1 EY Low Pinion Differentials L Mark a spot on the inside of the differential housing on the ring gear side in the position shown Fig 6 Ensure that the hole will be clear of the rib on the outside NOTE This position has been chosen to ensure that the airline and bulkhead fitting clear the factory swaybar L Cover the drive pinion area with a rag to protect it from metal filings L Secure the differential housing to the work bench L Drill an 11 2mm 7 16 diameter hole through the differential housing square to the inside surface Tap the hole from the outside using 4 NPT thread tap L Remove any sharp edges that may chip off from around the hole and fall into the housing Very carefully remove the rags and inspect with a service light inside the housing to insure no metal filings are left behind ARB 3 Installing the Air Locker 3 3 2 3 High Pinion Differentials L Mark a spot on the inside of the differential housing on the ring gear side in the position shown Fig 6 Ensure that the hole will be clear of the rib on the outside NOTE This position has been chosen to ensure that the airline and bulkhead fitting clear the factory suspension mounts L Cover the drive pinion area with a rag to protect it from metal filings Secure the differential housing to the work bench Drill an 11 2mm 7 16 diameter hole through the differ
3. 3 6 Installing the Seal Housing L Make sure the grooves and airway of the seal housing are clean and free from any contaminants e g water dirt metal filings etc L Inspect the seal housing O rings supplied for dirt damage or other conditions which might cause leaks L Generously lubricate the O rings with oil prior to assembly then insert them into the grooves of the seal housing NOTE When assembling the O rings be careful not to leave them twisted when seated in the grooves as this could cause excessive wear and leakage L Lubricate the seal housing running surface on the Air Locker carrier with oil L Carefully install the seal housing by sliding it all of the way onto the bearing journal with a gentle twisting motion until it sits flat against the adjuster nut NOTE A twisting motion i e a slight rotation while pressing the seal housing on will allow the O rings to engage gently and prevent them from twisting Twisted O rings will result in pre mature O ring wear and oil contamination in the air system due to the helical shape formed by the O ring mould line L Rotate the seal housing until the square cutout lines up with the locking tab position at the center of the bearing cap and then assemble the locking tab Fig 9 3 Installing the Air Locker L Install the spring clip by first hooking both ends of the clip into the small aligned cutouts of the seal housing an
4. 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 ARB 2 Removing the Existing Differential 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 L Set a dial indicator on one of the ring gear teeth Fig 2 L 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 L Rotat
5. the operator Make sure you have taken the following points into consideration L Switch es MUST be mounted and should never be allowed to simply dangle from the wiring loom during vehicle use L Switch es should be within easy reach of the driver Ideally any Air Locker switch should be able to be operated without physical effort or distraction to the driver L Switch es should be mounted within the line of sight of the driver so that switch position ON or OFF can be visually determined by the rocker position and the illumination state The position of the switch es should best eliminate any possibility of accidental operation by the driver or one of the passengers L Switch cutout position s must be located in an area with a minimum of 50mm 2 of clearance behind the face of the cutout L Switch es should not be mounted where they will be exposed to water e g in the lower section of an inner door panel ARB recommends that you apply the Air Locker Warning Sticker ARB part 210101 within close visual proximity of the switch location NOTE If no adequate position can be found on existing dashboard panels a surface mounted bracket Fig 22 may be purchased from your ARB Air Locker distributor to suit 1 2 or 3 switches ARB 5 Mounting amp Connecting the Electrical System 5 2 Wiring the Actuator System 5 2 1 Connection to an ARB AIR COMPR
6. A lubricant drain reservoir L A 11 2mm 7 16 drill and amp NPT tap for bulkhead fitting installation L An automotive bearing puller 2 jawed is recommended or a differential carrier bearing puller L A slide hammer L A bearing press or arbor press 1 2 2 Supplies L Thread lubricant sealant compound for pressure fittings e g LOCTITE 567 Teflon past L Thread locking compound e g LOCTITE 272 L 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 L A soap and water mixture to test for air leaks Replacement differential carrier bearings to upgrade to the 50mm Toyota bearing type ARB 2 Removing the Existing Differential 2 1 Vehicle Support L 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 L 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 L Clean around the differential drain plug to prevent dirt from entering the differential Position a fluid drain reservoir under the differential and loosen the differen
7. ESSOR When wiring the Air Locker actuator switch es and solenoid s to an ARB Air Compressor all connections can easily be set up directly from the supplied wiring loom Fig 23 NOTE 180409 model loom shown for reference only Refer to your ARB Air Compressor Installation Guide for details on configuring your installation FL TIS 4 8 TTERY 12V y be B 5 Mounting amp Connecting the Electrical System SWITCH IDENTIFICATION 5 2 2 Connection to an Alternate Air Source When connecting the actuation switch to an alternate air source the switch es should be wired according to figures 25 and 26 depending on whether one or two Air Lockers will be installed in the vehicle 5 2 2 1 Single Air Locker System L If only one Air Locker is to be installed in the system the switch and solenoid should be wired according to figure 25 regardless of whether the Air Locker has been installed in the front or rear axle of the vehicle Attach the appropriate switch cover i e FRONT or REAR to the switch NOTE Refer to figure 24 for the correct switch terminal identification and switch orientation SINGLE AIR LOCKER SYSTEM SOLENOID 1 3 PLUG IN ILLUMINATION TO IGNITION OR ISOLATING SWITCH TO DASH GROUND FITTING 7 SWITCH 1 5 Mounting amp Connecting the Electrical System 5 2 2 2 Dual Air Locker S
8. ING NOT SUPPLIED 12 1 SEAL HOUSING RETAINING CLIP 150601 13 1 SEAL HOUSING ASSEMBLY 081901 14 2 SEAL HOUSING O RINGS 160207 15 1 ADJUSTER NUT 100102 16 12 RETURN SPRINGS 150113 17 1 SPLINED SIDE GEAR 131415H 18 1 SPIDER BLOCK 070201 19 1 DIFFERENTIAL CASE 013014 1 THRUST BLOCK 110502 i 9 RING GEAR BOLT SPACER 4581061 ii 1 BULKHEAD KIT O RING TYPE 3 5 5mm 170105 2 1 5mm PUSH IN FITTING RI 5 1 8 170201 1 NIPPLE 1 8 BSP MALE TO MALE 170501 1 NYLON AIR LINE 5mm Dia X 6m long 170301 1 SOLENOID VALVE 180103 i 1 ON OFF SWITCH 180209 i 1 SWITCH COVER REAR 180211 li 10 CABLE TIE 180301 m 1 WARNING LABEL 210101 li 1 BUMPER STICKER 210102 i 1 OPERATING amp SERVICE MANUAL 210200 n 1 INSTALLATION GUIDE 2102136 ARB ARB PERFORMANCE CLUTCHES Not illustrated in exploded view TRANSMISSION AND DRIVETRAIN
9. an part 3810212S00 If your bolts are of a longer series i e 36mm 1 42 then you will need to use the spacers supplied under the bolt heads to prevent the threads from bottoming out or acquire the correct bolts from Nissan DO NOT MODIFY YOUR RING GEAR BOLTS A L Using a plastic or copper hammer tap in a circle around the ring gear to separate it from the differential carrier L Thoroughly clean any thread locking compound or other foreign matter from the holes of the ring gear the threads of the ring gear bolts the mating surfaces of the ring gear and the Air Locker flange HINT Rubbing the ring gear mounting face with a flat oil stone before installation will remove any high spots around the threads L 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 ARB 3 Installing the Air Locker NOTE NEVER HEAT GEARS WITH A FLAME This could damage the hardened surface of the gear and result in premature wear or failure L Dry the gear and tapped holes with compressed air if wet L Apply a thin film of high pressure grease to the ring gear shoulder of the Air Locker to prevent seizing L Install the ring gear onto the Air Locker by aligning the tapped holes and then gently tapping it around in a circle with a soft mallet or hammer Avoid using the bolts to pull the ring gear down as thi
10. d the adjuster nut and then snapping the clip into the groove of the seal housing using a screwdriver Fig 10 L Check that the seal housing is now secured from rotating and that it is still sitting flat against the adjuster nut 3 7 Setting up the Bulkhead Fitting L Apply thread sealant to the threads of the bulkhead body L Screw the bulkhead body into the tapped hole and tighten L Wipe the area clean of any excess thread sealant inside and outside of the housing L Without using sharp jagged tools such as pliers your hands are the best tool for this job bend the seal housing tube on the outside of the housing to approximate the finished profile This will allow the tube to be trimmed to a length that would allow it to protrude from the bulkhead fitting Fig 11 IMPORTANT The seal housing must still be able to freely float after the tube is connected to the bulkhead fitting Therefore it is critical to ensure that the tube is not under any tension To avoid this always leave the tube long enough so that a hook shape can be formed between the seal housing and the bulkhead ARB 3 Installing the Air Locker NOTE Use an automotive brake line tubing cutter to cut the seal housing tube never a hacksaw as this will leave metal filings in the air system L From the inside of the housing insert the trimmed tube into the bulkhead L From the outside of the housing assemble the sma
11. e it from the effects of vibration and shock Connect the air supply to the 1 8 BSP inlet port of the solenoid stamped 1 on the solenoid body using thread sealant IMPORTANT ARB cannot warrant your Air Locker s against damage caused as a result of using an alternate air supply If you have any doubts as to the suitability of your air system to use in an Air Locker system consult your ARB distributor ARB 4 Installing the Air System 42 Running and Securing the Air Line The path taken by the air line from your air source i e compressor to your Air Locker is unique to your vehicle and the position of your air source Plan ahead carefully when running the air line and always follow these guidelines L Account for axle travel when running the line from the axle to a fixed point on the vehicle Leave enough slack in the air line to allow for maximum suspension travel in both directions L Avoid leaving large lengths of air line hanging underneath the vehicle where they may get tangled on rocks sticks etc HINT Cable tying the air line to one of your flexible brake lines will account for axle travel and should help keep your line from getting snagged L Run the air line all the way from the compressor to the differential before trimming either end of the line to length This will save complications that may arise if the air line has to be removed L Make sure the line does
12. e the differential center 90 and measure again for accuracy L Record the average of all measurements ARB 2 Removing the Existing Differential 2 6 Removing the differential carrier L Remove the adjuster nut locking tabs L Remove the bearing caps from the third member L Remove the adjuster nuts L Carefully remove the differential carrier from the third member 2 7 Use of the Thrust Block As this Air Locker has been designed to cover a range of Nissan applications some installations may require a floating thrust block supplied to be inserted into the diff center If you are unsure whether this applies to you look down the splines of the OE diff you have removed from the vehicle to see if a thrust block used to maintain axle end float is present Remove the flange cap and splined side gear from the Air Locker L Insert the thrust block into the center of the diff L Replace the splined side gear and flange cap HINT A wad of thick grease will help to hold the thrust block in place during installation ARB 3 Installing the Air Locker 3 1 Mounting the Ring Gear Remove the bolts that hold the ring gear in place IMPORTANT Two different bolt lengths were used on this model of Nissan differential Measure the length of the bolts you removed shown as A in Figure 3 Your Air Locker was designed to use 31 5mm 1 24 bolts Niss
13. eel some backlash between the ring and pinion gears If not there might be a clearance problem which is binding the carrier Re check the clearance ARB 3 Installing the Air Locker 3 5 Checking the Backlash L Set a depth indicator on one of the ring gear teeth Fig 8 L 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 L Rotate the differential center 90 and measure again for accuracy L Refer to your vehicle service manual for the specified maximum and minimum amounts of backlash IMPORTANT It is critical to set up bearing pre load when a differential is installed 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 L Adjust the backlash and pre load using an adjuster nut wrench to tighten or loosen the adjuster nuts as required Refer to your vehicle service manual L Recheck backlash as before repeating this procedure until backlash is within the specified amount L Tighten the bearing cap bolts with a torque wrench to the torque specified in your vehicle manufacturer s service manual nn 3 Installing the Air Locker
14. em recharging within that time period would indicate that a leak is present in the system NOTE Ifan alternate air source e g an air cylinder or a belt driven air pump is used instead of a compressor the air system will have to be leak tested with a pressure gauge and a shut off valve in series before the solenoid input Fig 19 L If a leak is found to be present spray a soap and water mixture onto all air fittings in the system while the compressor is fully charged Bubbles should appear at any leak points L Check that leaky fittings have been adequately tightened Disassemble clean threads and reapply thread sealant if leaking persists 6 2 Testing the Air Locker Actuation To test that your air system electrical system and your Air Locker differential is functioning correctly Support the vehicle such that the wheels are free to rotate e g on axle stands a chassis hoist etc L Leave the parking brake off the transmission in neutral and the Air Locker switch OFF L Turn the ignition to the ON position leaving the motor off The large illuminating symbol on the Air Locker switch cover should be OFF ARB 6 Testing amp Final Assembl L Turn the compressor or alternate air source on to charge the air supply up to its maximum pressure L Rotate one wheel by hand L The wheel should rotate freely and the opposite wheel should be turn
15. ential housing square to the inside surface L Tap the hole from the outside using 4 NPT thread tap L Remove any sharp edges that may chip off from around the hole and fall into the housing Very carefully remove the rags and inspect with a service light inside the housing to insure no metal filings are left behind 3 Installing the Air Locker 3 4 Final Air Locker Assembly L Clean all parts of the differential assembly paying particular attention to the seal housing journal L Place the Air Locker into the differential housing and install the bearing caps NOTE Be sure to check that the bearing caps are on the correct sides of the third member and are correctly aligned L Insert the bearing cap bolts and hand tighten NOTE Before attempting to install the adjuster nuts make sure the threads on the inside of the bearing caps and differential housing are perfectly aligned If they are not the threads could be stripped Insert and lightly hand tighten the adjuster nut supplied with the Air Locker kit into the ring gear side bearing cap NOTE You should feel no backlash between the ring and pinion gears once the adjuster nut tightens Reverse the adjuster nut counterclockwise 1 4 turn L Insert the original adjuster nut onto the opposite side of the differential and tighten with the appropriate adjuster nut wrench NOTE You should now f
16. erfere with the bearing caps the Air Locker the ring gear or the axle housing Ensure at least 8mm 5 16 clearance between the seal housing tube and the Air Locker 3 Installing the Air Locker IMPORTANT In order for the seal housing to float and self center on the bearing journal the seal housing tube must not be pulling against the seal housing To check this rotate the drive flange back and forth while observing the seal housing movement The seal housing should rotate slightly against the spring clip but it should not appear to pull away from the face of the adjuster nut IMPORTANT Check that the tail of the adjuster nut locking tab does not push on the seal housing Bend it up away from the seal housing with a screw driver if necessary ARB 3 Installing the Air Locker 3 8 2 EJ High pinion Differentials With the seal housing tube now firmly secured into the bulkhead fitting bend the tube so that it closely follows the profile of the differential Figs 16 17 amp 18 L Check that the contour of the tube will not interfere with the bearing caps the Air Locker the ring gear or the axle housing Ensure at least 8mm 5 16 clearance between the seal housing tube and the Air Locker s 3 Installing the Air Locker IMPORTANT In order for the seal housing to float and self center on the bearing journal the seal housing tube must not be pulling against the seal housing T
17. ing in the opposite direction without any resistance or mechanical noise from within the differential L Turn the Air Locker switch to the ON position The illuminated symbol on the switch cover should light up L Rotate the same wheel again L Both wheels should rotate together L Turn the switch off again L Rotate the same wheel L The wheels should again rotate in opposite directions 6 3 Filling the Differential NOTE Consult the ARB Air Locker Operating amp Service Manual for recommendations on differential lubricant specifications L Refill the differential until level with the filler hole L Rotate the differential center 2 full turns Check the oil level and add oil if necessary Apply thread sealant to filler plug before inserting Replace the filler plug Clean the differential housing of any oil or grease that may collect dirt or other abrasive particles ARB 6 Testing amp Final Assembl 6 4 Post Installation Check List Now that the Air Locker installation has been completed ARB recommends that you take the time to complete the following check list just to insure that you haven t missed any of the vital steps L The air system has been leak tested L Thread locking compound was used on the ring gear bolts All torque settings comply with the vehicle manufacturer s specs and were set with an accurate torque wrench L Diffe
18. 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 y mark inside each of the symbols as you complete each step It is very important NOT to miss any of the steps ARB 1 Introduction 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 L Standard automotive sizes metric and or imperial of sockets wrenches Allan keys and drills L A dial indicator or other suitable measuring tool for checking ring amp pinion backlash L An adjuster nut wrench See your vehicle service manual A razor knife suitable for cutting nylon tubing L A torque wrench See your vehicle service manual for the required torque range
19. line small end first Fig 21 Insert the outer compression nut over the air line L Insert the 5mm 0 197 ferrule over the end of the air line Leave approx 5mm of tubing between the ferrule and the end of the tube SUPPORT SPRING OUTER COMPRESSION NUT FERRULE 5 0mm 0 197 SUPPORT TUBE Insert the support tube all the way into the end of the air line ARB 4 Installing the Air System HINT If the support tube is too difficult to insert place the end of the air line into a cup of boiled water to soften the tubing L Insert the tube end all the way into the center compression nut L Screw on the outer compression nut and tighten The ferrule and support tube are now permanently attached L Assemble the support spring over the outside of the outer compression nut L Secure any loose sections of tube with a cable tie ARB 5 Mounting amp Connecting the Electrical System 5 1 Mounting the Actuator Switch es Air Locker actuator switch es can be easily panel mounted inside the vehicle in a 21mm x 36 5mm 0 83 x 1 44 rectangular cutout NOTE Only attach the cover plate to the face of the switch once the switch has been mounted and wired correctly as the cover plates are designed to be difficult to remove For reasons of safety and for ease of operation the Air Locker actuator switch es should be mounted in a location picked to best suit
20. ll O ring over the top of the short length of seal housing tube protruding through the bulkhead fitting L While holding the seal housing tube into the bulkhead fitting insert the small drilled end of the center compression nut over the extended tube as shown in the assembly diagram Fig 12 and screw it into the bulkhead body and lightly tighten NOTE Besureto insert the correct end of the center compression nut into the bulkhead body The thread has been partially relieved on the bulkhead side of the center compression nut to visually identify its orientation Fig 12 3 Installing the Air Locker CENTER lt COMPRESSION NUT jq BULKHEAD BODY DIFFERENTIAL HOUSING SEAL HOUSING TUBE TO SEAL HOUSING NOTE Excessive tightening of the center compression nut is not necessary to form a good seal around the tube and may damage the O ring the seal housing tube or the threads of the compression nut NOTE Make sure the seal housing tube is all of the way into the center compression nut while you are tightening it ARB 3 Installing the Air Locker 3 8 Profiling the Seal Housing Tube 3 8 1 EY Low pinion Differentials With the seal housing tube now firmly secured into the bulkhead fitting bend the tube so that it closely follows the profile of the differential Figs 13 14 amp 15 L Check that the contour of the tube will not int
21. noid exhausts compressed air through the center of the black retaining cap when the Air Locker is disengaged Make sure this orifice cannot be obstructed L Apply Teflon paste to the threads of the 5mm push in fitting and assemble it into the solenoid outlet port stamped 2 and tighten 5mm PUSH IN FITTING 4 Installing the Air System 4 1 2 Connection to an Alternate Air Source For ease of installation quality of air supply and a high level of dependability from your Air Locker s ARB strongly recommends use of a genuine ARB Air Compressor however the Air Locker air system can be operated on any alternate air source that meets each of the following guidelines L Must supply a minimum of 586 kPa 85 PSI The supply must never exceed 724 kPa 105 PSI L The air source should have a tank capacity which enables it to actuate the Air Locker s in one charge so that no hesitation is experienced when locking one or two differentials HINT A good way to insure that you have the necessary capacity is to make sure you can engage disengage and then reengage your Air Locker s without the air source having to regenerate e g without the compressor turning on to refill the tank L Must supply clean air free of rust dirt water or other foreign matter L Must match the 1 8 BSP porting of the Air Locker solenoid Mount solenoid within close proximity of the air supply and secur
22. not contact sharp edges or abrasive surfaces that may damage the air line over time Do not run the air line around tight bends that may kink the air line and restrict or block the air flow L Keep the air line well away from your vehicle s exhaust components Air lines will melt if subjected to extreme heat L Do not run more air line than necessary Excess line volume created when coiling the left over hose using unusually large diameter hose etc will increase drain on the compressor tank resulting in the compressor running more often than needed L Support the air line by tying it back with cable ties wherever possible At the solenoid end of the air line trim the line to length with a sharp knife L To attach the air line to the push in fitting of the solenoid insert the line firmly into the fitting pull outward on the flange of the fitting while holding the line as far into the fitting as possible and then gently pull outward on the air line to clamp the line in place ARB 4 Installing the Air System NOTE Toremove the air line from the push in fitting pull outward on the flange of the fitting push the air line as far into the fitting as possible and hold push inward on the flange and then pull the air line free of the fitting 43 Connection to the Bulkhead Fitting L Trim the air line to length using a sharp knife L Insert the support spring over the end of the air
23. o check this rotate the drive flange back and forth while observing the seal housing movement The seal housing should rotate slightly against the spring clip but it should not appear to pull away from the face of the adjuster nut IMPORTANT Check that the tail of the adjuster nut locking tab does not push on the seal housing Bend it up away from the seal housing with a screw driver if necessary 3 Installing the Air Locker 3 9 Bench Testing the Air Locker L To test the Air Locker when 620kPa 90 PSI shop air is applied to the seal housing tube the Air Locker should engage Check all fittings and the seal housing for air leaks Rotate the differential carrier by turning the pinion flange whilst applying air pressure NOTE An accurate way to test for air leaks is to fit a shut off valve to an air pressure gauge Available as ARB part ALTGO01 Charge with shop air until 620 KPA 90 PSI is reached shut the valve off disconnect the air hose and watch to see if there is any drop in pressure Any gradual pressure drop indicates an air leak Fig 19 Figure 19 L If a leak is found to be present spray a soap and water mixture onto the bulkhead air fitting Bubbles should appear at any leak points NOTE Do not spray this soapy mixture inside the differential L Check that leaky fittings have been adequately tightened Disassemble clean threads and reapply
24. rential fluid complies with ARB recommendations and has been filled to the correct level All air lines and wiring have been securely cable tied to resist snagging L Switch es have been securely mounted within operator reach yet well away from danger of accidental engagement L Switch es function properly and illuminate to indicate that Air Locker s are engaged All operators who are to use the Air Locker have read and fully understand the ARB Air Locker Operating amp Service Manual L The Air Locker Warning Sticker has been located within close proximity of the actuator switch es INSTALLATION PERFORMED BY DATE OF INSTALLATION ODOMETER READING ARB AIR LOCKER SERIAL No ARB 7 Parts List 7 4 Exploded Assembly Diagram See itemized parts list overleaf NISSAN H233B 31 SPL RD136 i 7 Parts List 7 2 Itemized Parts List See exploded diagram Figure 27 AIR LOCKER MODEL No RD136 ITEM QTY DESCRIPTION PART 01 1 FLANGE CAP ASSEMBLY 027314 02 1 BONDED SEAL 160703 03 1 CLUTCH GEAR 050804 04 4 SHORT CROSS SHAFT 060403 05 4 PINION GEAR 140701R 06 4 PINION THRUST WASHER 151110 07 1 SIDE GEAR 131315H 08 2 SIDE GEAR THRUST WASHER 151010 09 2 COUNTERSUNK SCREW 200213 10 4 RETAINING PIN 120601 11 TAPERED ROLLER BEAR
25. s puts excess strain on the bolts and the differential flange L Apply a thread locking compound to the thread of each ring gear bolt before inserting it Do not apply locking compound directly into the threaded hole as this could prevent the bolt from reaching its full depth NOTE On some models the crown wheel bolts cannot be reused and should therefore be replaced Refer to your vehicle manufacturer s service manual for details L Tighten the ring gear bolts in a star pattern with a torque wrench Fig 4 set to your vehicle manufacturer s specified torque 3 Installing the Air Locker 3 2 Installing the Carrier Bearings The Air Locker has been designed to employ higher rated 50mm carrier bearings instead of the 45mm carrier bearings used on the OE Nissan diff center Due to this it is not possible to re use the original bearings and 50mm bearings must be purchased Timken 32010X 32010X ARB 160116 L Apply a thin film of high pressure grease to the bearing journals of the Air Locker then press the bearing cones onto the bearing journals as shown in Figure 5 Figure 5 ARB 3 Installing the Air Locker 3 3 Drilling and Tapping the Bulkhead Port An air line port must be drilled and tapped through the differential housing to mount the bulkhead fitting into For low pinion differentials follow instruction A For high pinion differentials follow instruction
26. thread sealant if leaking persists L If a leak is found at the seal housing carefully remove and refit Be very careful with the O rings and check they have not been damaged during installation ARB 3 Installing the Air Locker 3 10 Reinstalling Differential and Axles L Replace the paper gasket on the axle housing flange L Reinstall the third member to the differential housing according to your vehicle service manual L Reinstall the drive shaft L Replace the axle seals if necessary and fit to the axles L Insert both axles fully into the housing engaging splines and then gently tap them inward NOTE Be careful not to damage the axle shaft oil seals when installing the axle Support the axle s entire weight where possible L Torque down the axle bolts to manufactures specifications ARB 4 Installing the Air System 4 1 Mounting the Solenoid 4 1 1 Connection to an ARB Air Compressor Fig 20 L Remove one of the 1 8 BSP plugs from its port in the compressor tank L Apply Teflon paste to the nipple 1 8 X 1 8 BSP and insert it into the port and tighten L Apply Teflon paste to the free end of the nipple L Assemble the inlet port side of the solenoid stamped with a 1 onto the nipple and hand tighten it The solenoid should be rotated into a position that does not obstruct any other ports on the compressor tank NOTE The sole
27. tial drain plug L 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 Removal of the Axles and Differential Remove the axles according to your vehicle s service manual HINT When removing the axles try not to damage the paper gaskets behind the axle flanges L Disconnect the drive shaft from the flange of the differential L 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 ARB 2 Removing the Existing Differential 2 4 Marking the Bearing Caps L 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 L Mark the right hand cap in a similar way HINT Many installers choose to make one punch mark on the left hand
28. ystem L If two Air Lockers are to be installed in the system ARB recommends that the switches and solenoids be wired according to figure 26 For safety reasons this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on Attach the REAR AIR LOCKER switch cover to SWITCH 1 and the FRONT AIR LOCKER switch cover to SWITCH 2 identification and switch orientation NOTE Refer to figure 24 for the correct switch terminal L Configure SOLENOID 1 as the air line leading to the rear axle Air Locker and SOLENOID 2 as the air line leading to the front axle Air Locker DUAL AIR LOCKER SYSTEM ILLUMINATION ISOLATING SWITCH GROUND TO IGNITION OR TO DASH SOLENOID 1 EIEI T Oo c 2 z PLUG IN FITTING SWITCH 2 SOLENOID 2 o IEE Pa PLUG IN p ARB 6 Testing amp Final Assembl 6 1 Leak Testing L With the vehicle parked and the engine off turn the compressor on and wait until the air system is fully charged NOTE With the Air Locker s disengaged the air source i e compressor should not have to recharge over time Intermittent recharging without Air Locker use usually indicates a leak at the solenoid fittings or at the compressor tank O ring seal L Actuate the Air Locker s L The compressor should not come on again for a period of at least 15min Air syst
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