ARB® Air Locker™ Locking Differential, Front Dana 35
Contents
1. Do not run the air line around tight bends which may kink the air line and restrict or block the air flow Keep the air line well away from your vehicle s exhaust components Air lines will melt if subjected to extreme heat 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 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 To remove the air line from the push in fitting while holding the flange of the fitting out push the air line into the fitting as far as possible then press the flange inward then pull the air line free of the fitting ARB _ ___ 5 Installing the Air System 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 5 3 Connection to the Bulkhead Fitting Trim the air line to length using a sharp knife Insert the support spring over the end of the air line small end first Fig 24 Insert the outer compression nut over the air line Insert t2. 08 1 PISTON Polyamide 040103 09 1 BONDEDSEL 160700 10 1 CYLINDER CAP 03012235 11 2 SEALHOUSINGO HING 160208 12 6 CYLINDER CAP RETAINING BOLT 200205 13 6 TABWASHER 8mm 150400 14 TAPEREDROLLER BEARING NOTSUPPLED 15 1 SEALHOUSING 000 16 1 SHMKT SHKOO4 17 1 SPLINED SIDE GEAR 130307 18 4 PINION THRUST WASHER 151101 19 4 PINONGEAR 140000 20 1 SPIDERBLOCK 070100 1 THRUST BLOCK THREADED 110401 _ 21 1 THRUST BLOCK 110001 22 1 SIDEGEAR 130107 1 BULKHEADFITTING O RING TYPE 170105 1 PUSH IN FITTING 5mm R15 1 8 170201 1 AIRLINE 5mm DIAX6m LONG 170301 1 NIPPLE 1 8 MALE 170501 _ 1 SOLENOIDVALVE 18003 1 ACTUATORSWITCH 1802090 1 SWITCHCOVER REAR 18021 1 SWITCHCOVER FRONT 180200 _ 10 9 180900 1 WARNINGLABEL 2100 1 BUMPERSTICKER 21002 J 1 OPERATING amp SERVICE MANUAL 210200 1 INSTALATIONGUDE 2102007 Not illustrated in exploded view ARB _ _ PERFORMANCE CLUTCHES TRANSMISSION AND DRIVETRAIN
3. With the Air Locker well supported in an arbor press apply a thin film of high pressure grease to the ring gear side bearing journal and assemble the newly established shim pack onto the bearing journal Press the tapered roller bearing cone onto the bearing journal of the differential carrier until the bearing seats firmly against the shim pack NOTE Never re use any bearings which are damaged or worn _ Invert the Air Locker and apply a thin film of high pressure grease to the seal housing side bearing journal Press a second bearing cone onto the opposite bearing journal taking care not to damage the O ring grooves Figure 6 ZA f V 4 C Px n V m Pi A 4 lt amp gt F vam NOTE Do not add any shims between the seal housing bearing and the bearing seat ARB 4 Installing the Air Locker 4 2 Installing the Thrust Block IMPORTANT This model of Air Locker was manufactured to replace Nissan differentials which employ one of three distinctly different methods of retaining the axle shafts 1 Full Floating Axles 2 Semi Floating Axles 3 IFS Bolt Retained Axle Stubs Depending on which axle type you have you may be required to install one of the thrust blocks included with the Air Locker kit before mounting the ring gear 4 2 4 Full Floating Axles Full floating axles are completely supported
4. is disengaged Make sure this orifice cannot be obstructed Apply Teflon paste to the threads of the 5mm push in fitting and assemble it into the solenoid outlet port stamped 2 and tighten AIR LINE TO DIFFERENTIAL 5mm PUSH IN FITTING 5 Installing the Air System 5 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 Must supply a minimum of 85PSI b86kPa The supply must never exceed 105PSI 724kPa The Air source should have a tank capacity that 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 Must supply clean air free of rust dirt water or other foreign matter Must match the 1 8 BSP porting of the Air Locker solenoid Mount solenoid within close proximity of the air supply and secure it from the effects of vibration and shock Connect the air supply
5. all connections can easily be set up directly from the supplied wiring loom Fig 26 NOTE Refer to your ARB Air Compressor Installation Guide for details on configuring your installation 6 Mounting 8 Connecting the Electrical System ARB AIR COMPRESSOR WIRING LOOM PRESSURE DK BLU LIMIT SWITCH Z SOLENOID 1 SOLENOID 2 o o COMPRESSOR I MOTOR PLUG IN 5 v FITTING PLUG IN H PLUG IN s FITTING gt FITTING TO IGNITION ILLUMINATION D E ag ISOLATION SWITCH BLU WHT _TO DASH RED YEL SWITCH 1 m K BATTERY 12V Sb SWITCH 2 TERMINAL IDENTIFICATION 6 Mounting amp Connecting the Electrical System 6 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 28 and 29 depending on whether one or two Air Lockers will be installed in the vehicle 6 2 2 1 Single Air Locker System If only one Air Locker is to be installed in the system the switch and solenoid should be wired according to figure 28 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 27 for the correct switch terminal identification and switch orientation SINGLE
6. and the opposite wheel should be turning in the opposite direction without any resistance or mechanical noise from within the differential Turn the Air Locker switch to the ON position The illuminated symbol on the switch cover should light up Rotate the same wheel again Both wheels should rotate together Turn the switch off again Rotate the same wheel The wheels should again rotate in opposite directions 7 3 Re Sealing amp Filling the Differential NOTE Consult the ARB Air Locker Operating amp Service Manual for recommendations on differential lubricant specifications Replace the differential cover using gasket sealant or a new standard differential cover gasket for your make of vehicle Refill the differential until level with the filler hole Rotate the differential center 2 full turns Check the oil level and add oil if necessary Replace filler plug apply thread sealant to filler plug before inserting if it is a threaded type plug Wipe differential housing clean of any oil or grease which may collect dirt or other abrasive particles ARB _ ___ 7 Testing 8 Final Assembly 7 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 The air system has been leak tested Thread
7. and therefore do not require a thrust block at all 4 2 2 Semi Floating Axles Semi floating axles are only retained inward at the wheel end of the axle shaft and are supported in the center of the axle assembly by a thrust block With the Air Locker positioned with the cylinder cap bolt heads facing down cut the cable ties and remove the flange cap from the assembly Remove the splined side gear from the assembly Insert the thrust block ARB Part 110501 into the hole in the center of the spider block Re assemble the side gear and the flange cap ARB 0 00 4 Installing the Air Locker 4 2 3 IFS Bolt Retained Axle Stubs IFS assemblies retain one of the axle stubs with a long bolt through the center of the shaft This requires that a threaded thrust block be installed into the side gear of the Air Locker With the Air Locker positioned with the cylinder cap bolt heads facing down cut the cable ties and remove the flange cap from the assembly Remove the splined side gear from the assembly Insert the threaded thrust block ARB Part 110401 through the hole in the center of the spider block and into the spline of the side gear Refer to Fig 7 Figure 7 Using an aluminum or hard plastic drift knock or press the thrust block into the spline until it reaches its maximum depth Fig 8 amp 9 NE LL Lm 22 d Figure 8 Re assemble the side gear and the
8. flange cap ARB 4 Installing the Air Locker 4 3 Mounting the Ring Gear IMPORTANT Your Air Locker was manufactured to replace differentials using 12mm 0 472 diameter ring gear bolts Ring gears with smaller bolts should ONLY be installed using cylindrical spacers to reduce the clearance between the bolts and the Air Locker flange not supplied 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 of the ring gear and the Air Locker flange NOTE Rubbing the ring gear mounting face with a flat oil stone before installation will remove any high spots around the threads Heat the ring gear to between 80 and 100 C 175 212 F in an oven or in hot water 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 ring gear with compressed air if wet paying particular attention to the threaded holes Install the ring gear onto the Air Locker by aligning the holes in the flange with the tapped holes in the ring gear then gently tapping it around in a circle with a plastic or copper hammer NOTE Avoid using the bolts to pull down the ring gear as this pu
9. 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 Differential 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 Switch es have been securely mounted within operator reach yet well away from danger of accidental engagement Switch es function properly and illuminate to indicate that Air Locker s have been engaged All operators who are to use the Air Locker have read and fully understand the ARB Air Locker Operating amp Service Manual 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 _ ___ 8 Parts List 8 1 Exploded Assembly Diagram See itemized parts list ov 3NI1dS 6c 00 9 00 9 NVSSIN LOLOY 8 Parts List 8 2 Itemized Parts List See exploded diagram figure 30 AIR LOCKER MODEL No RD107 01 1 FLANGE CAP L 0200 02 1 CLUTCHGEAR 00 03 1 DIFFERENTIALCASE 000 04 4 PISTONSPHNG 100 05 2 CROSS SHAFT RETAININGPIN 120102 2 CROSSSHAFTRETAININGPIN 120302 06 4 SHORTCROSSSHAFT 060300 07 2 SIDEGEARTHRUSTWASHER 151003
10. AIR OPERATED LOCKING DIFFERENTIALS INSTALLATION GUIDE Part No 2102107 viston Date 22 06 04 Copyright 2003 by Pi 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 11 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 fro
11. Air Locker SYSTEM SOLENOID 1 ILLUMINATION TO IGNITION OR ISOLATING SWITCH TO DASH GROUND SWITCH 1 6 Mounting amp Connecting the Electrical System 6 2 2 2 Dual Air Locker System _ If two Air Lockers are to be installed in the system ARB recommends that the switches and solenoids be wired according to figure 29 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 NOTE Refer to Figure 27 for the correct switch terminal identification and switch orientation 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 TO DASH ILLUMINATION TO IGNITION OR ISOLATING SWITCH SOLENOID 1 SOLENOID 2 SWITCH 1 PN PLUG IN Nd PLUG IN G FITTING o FITTING I O u 7 Testing 8 Final Assembly 7 1 Leak Testing With the vehicle parked and the engine off turn the compressor on and wait until the air system is fully charged 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 Actuate the Air Locker s T
12. Any binding or stiffness could mean that the threaded thrust block was not seated fully or was not seated straight If this is the case then the thrust block position must be corrected in order to correctly set up the Air Locker and to prevent damage to the Air Locker and to the axle stub To correct the thrust block position pull the trust block into its seat in the side gear spline using a slide hammer on the axle stub or by using a large flat washer over the end of the bearing journal and pulling the thrust block into place with the bolt Once the axle stub is turning freely while the bolt is hand tight re tighten the bolt using a torque wrench according to the torque specification in your vehicle manufacturer s service manual Again make sure the axle stub is turning freely 5 Installing the Air System 51 Mounting the Solenoid 5 1 1 Connection to an ARB Air Compressor Fig 23 Remove one of the 1 8 BSP plugs from its port in the compressor tank Apply Teflon paste to the nipple 1 8 X 1 8 BSP and insert it into the port and tighten Apply Teflon paste to the free end of the nipple Assemble the inlet port side of the solenoid stamped with a 1 onto the nipple and tighten The solenoid should be rotated into a position that does not obstruct any other ports on the compressor tank The solenoid exhausts compressed air through the center of the black retaining cap when the Air Locker
13. alling the Air Locker 4 5 Assembling the Differential Carrier Relieve all tension on the housing spreader Place the bearing cup over the bearing cone Figure 11 ONISNOH 1V3S MOVd WIHS WIHS 43LSvVW Slide the seal housing into place against the bearing cup stepped side out The grooves in the bearing journal under the seal housing will house the O rings in the final assembly but they will not be installed now to avoid damage to the O rings Install the supplied master shim onto the seal housing NOTE The shim pack cannot be installed at this time as the required thickness shown as E in Figure 11 has yet to be determined ARB ___ 4 Installing the Air Locker Hold the bearing cup in place on the ring gear side Holding the master shim and tapered roller bearing cup in place at each end insert and hold the Air Locker into the differential housing with the seal housing tube pointing straight out of the housing Install one bearing cap on the ring gear side The bearing cap the seal housing side will need to be drilled or slotted as clearance for the seal housing tube Install the bearing cap bolts finger tight Push the Air Locker hard across to the ring gear side and measure the gap end float between the master shim and the housing with a feeler gauge Consult your vehicle manufacturer s service manual to determine the carrier bearing pre load am
14. allow the O rings to gently engage Assemble the shim pack and master shim Point the seal housing tube straight out of the housing hold the shims and tapered roller bearing cups in place and insert and hold the Air Locker into the differential housing Install the bearing cap on the ring gear side Check to see if the bearing cap on the seal housing side fits over the tube without fouling NOTE Do not forget to check the bearing caps are turned the correct way around Install all bearing cap bolts and torque to manufacturer s specs 49 Final Backlash Checking Relieve all tension on the housing spreader Tighten all bearing cap bolts with a torque wrench to the torque specified in your vehicle manufacturer s service manual Set a depth indicator on one of the ring gear teeth as in Figure 18 While supporting the pinion gear by holding the drive shaft 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 ARB _ ___ 4 Installing the Air Locker Figure 18 Refer to your vehicle service manual for the specified maximum and minimum amounts of backlash If the backlash is not within the specifications then the differential will have to be remo
15. asurement 3 1 Measurement for Pre Load Shimming When fitting an ARB Air Locker a variable shim pack supplied is used in conjunction with the original bearing on the right hand side of the differential as pictured in Fig 11 in order to achieve the correct ring and pinion backlash and carrier bearing pre load once the Air Locker has been installed Because of this the original shim from this side will not be reused The original bearing type and shim type are used on the left hand ring gear side of the Air Locker as pictured in Fig 5 Measurements will however need to be taken to determine the correct shim thickness for this side in order to reproduce a similar backlash and pre load to that of your existing differential The large spacer on the outside of the ring gear side shim must be retained and re fitted when the Air Locker is installed NOTE Keep the shims separated so that they can be identified as to which end of the differential they came from Secure the 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 from the differential center using a bearing puller Using a caliper or similarly accurate measurement method i e able to take accurate measurements within 0 04mm 0 0015 hold the bearing cup in pla
16. cap bolts ARB _ ___ 4 Installing the Air Locker It is very important to make sure the punch marks made on the differential housing while removing the differential are matched to the punch marks on the bearing cap The bearing cap must be replaced exactly as it was removed Refer to section 2 4 Measure to the bearing cap from exactly the same position on the differential housing that you took the previous measurements from Fig 14 Mark the tube position where the clearance is to be made for the seal housing tube with a center punch Remove the bearing cap from the differential housing Measure the distance from the center punch mark made on the bearing cap to the closest edge of the bearing cap If the center punch mark is greater than 5mm 3 16 from the closest edge of the bearing cap it is recommended that a small hole be drilled through the bearing cap Section 4 7 2 If less than 5mm 3 16 from the edge it is recommended that a notch is filed into the side of the bearing cap to avoid break through while drilling Section 4 7 3 ARB _ ___ 4 Installing the Air Locker 4 7 2 Drilling the Bearing Cap Hold the bearing cap steady for drilling in a soft jawed vise clamp NOTE Do not apply too much clamping pressure with the vise The bearing cap may be damaged Using a pedestal drill drill a 5mm 3 16 hole through the bearing cap where the seal housing tube hole has b
17. ce and measure the distance from the shoulder of the bearing journal to the ring gear mounting face shown as A in Figure 4 and record this measurement as A Measure the thickness of the shim not the spacer removed from the ring gear side of the differential carrier shown as B in Figure 4 and record this measurement as B Measure the distance from the Air Locker bearing shoulder to the ring gear mounting face shown as C in Figure 5 and record this measurement as C ARB _ ___ 3 Bench Measurement SPACER f FACTORY SPACER 3 Bench Measurement 3 2 Calculation amp Selection of Shims The thickness of the shim pack required for the Air Locker shown as D in Figure 5 can now be determined by substituting the measurements taken into the following equation HINT If your calculations are correct then the following equation will also be true A B G D ZERO To make a shim pack to match the measurement you calculated as D you can Either machine the ring gear side shim or purchase a new one of the correct thickness from your Nissan dealer Add shims between the master shim and the seal housing Use a universal shim kit available from most drive train specialists NOTE Never re use any shims which are damaged or worn _ ___ 4 Installing the Air Locker 41 Installing the Carrier Bearings
18. e A lubricant drain reservoir Suitable measuring tools to measure a differential for pre load and or backlash shimming See Section 3 Bench Measurement JA 11 2mm 7 16 drill and 24 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 e g LOCTITE 567 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 A selection of differential bearing shims to set up pre load and backlash See section 3 Bench Measurement ARB _ ___ 2 Removing the Existing Differential 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 ata 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 cover plate seal to pre
19. e the differential center 90 and measure again for accuracy Record the average of all measurements ARB _ _ ___ 2 Removing the Existing Differential 2 6 Spreading the Differential Housing IMPORTANT Spreading the differential housing with a differential case spreader is a step which 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 Unbolt and remove the bearing caps from the differential housing HINT Be sure not to mix up the left and right hand bearing caps Later it will be necessary to know which cup came from which bearing and which shim came from which side 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 Once the housing has been adequately spread the differential may be removed by pulling forward on the differential carrier de 4 Cle Rx Te Hil t wl a A Pe O d xL 2 NOTE Keep the shims separated so that they can be identified as to which end of the differential they came from Immediately release all spreader tension once the differential center has been removed ARB 3 Bench Me
20. een marked Fig 15 A Figure 15 Remove the bearing cap from the vise turn it upside down and re clamp it in the vise The drilled hole must be chamfered approximately 3mm 1 8 to remove any sharp edges that may chip off and fall into the housing Fig 16 Installing the Air Locker Figure 16 4 7 3 Notching the Bearing Cap Use a soft jawed vise clamp to hold the bearing cap steady Using a 6 35mm 14 rat tailed file File out a notch in the bearing cap from the closest edge until an adequate notch has been cut around the position of the punch mark Fig 17 File a chamfer around the inside edge of the notch to remove any sharp edges from the notch that may chip off and fall into the housing 4 8 Air Locker Final Assembly ARB 4 Installing the Air Locker Remove the seal housing shim pack and master shim and clean all parts of the differential assembly It is very important to make sure the seal housing grooves are free from any contaminants eg water dirt metal fillings etc Lubricate the O rings with oil prior to assembly then stretch them over the bearing journal and release them into the grooves NOTE Do not roll the O rings onto the seal housing as this will damage them Place the bearing cups onto their respective bearing cones Install the seal housing over the O rings by gently applying a downward twisting motion This will
21. he 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 ___ 5 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 Insert the tube end all the way into the center compression nut Screw on the outer compression nut and tighten The ferrule and support tube are now permanently attached Assemble the support spring over the outside of the outer compression nut Secure any loose sections of tube with a cable tie ARB ___ 6 Mounting amp Connecting the Electrical System 6 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 the operator Make sure you have taken the following points into consideration S
22. he compressor should not come on again for a period of at least 15min Air system recharging within that time period would indicate that a leak is present in the system If an 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 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 Check that leaky fittings have been adequately tightened Disassemble clean threads and reapply thread sealant if leaking persists 7 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 Leave the parking brake off the transmission in neutral and the Air Locker switch OFF ARB _ ___ 7 Testing 8 Final Assembly Turn the ignition to the ON position leaving the motor off The large illuminating symbol on the Air Locker switch cover should be OFF Turn the compressor or alternate air source on to charge the air Supply up to its maximum pressure Rotate one wheel by hand The wheel should rotate freely
23. he 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 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 Set a depth indicator on one of the ring gear teeth as in figure 2 While supporting the pinion gear by holding the drive shaft 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 Rotat
24. he time of re assembly Please determine if they apply to your assembly and follow them accordingly 4 12 1 Nissan MQ Patrol Front Differential NOTE This section applies to the front differentials of Nissan MQ Patrols only Both axle shafts are to be modified as described below _ The left hand front axle must have part of the raised section machined away to prevent the axle shaft from fouling the Air Locker The necessary modification is shown in Figure 21 _ ___ 4 Installing the Air Locker MAX 10mm 3 8 IMPORTANT Ensure that material is only removed from the section shown in the sketch above If too much is removed the oil seal may allow differential oil to leak into the wheel hub To prevent the end of the right hand front axle shaft from bottoming out on the thrust block it must be shortened by 10mm NOTE To be safe you should try the axles in position first to make sure they have not already been modified 4 12 2 Nissan IFS R200A Differential NOTE This section applies only to the front differentials of Nissan IFS vehicles that use a single bolt to secure the short axle stub into the differential side gear Insert the axle stub as far as it will go Insert and hand tighten the retaining bolt into the center of the axle stub Refer Fig 22 ARB _ ___ 4 Installing the Air Locker Check that the axle stub turns freely IMPORTANT
25. m 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 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 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 amp pinion backlash JA standard automotive feeler gauge _ Automotive brake tubing cutters to cut the steel tubing J A razor knife to cut the nylon tubing A differential housing spreader to facilitate removal of the carrier A torque wrench See vehicle service manual for required torque rang
26. nly and will not be used for final assembly 4 6 1 Re Shimming the Backlash NOTE This step is only necessary when adjusting for incorrect backlash Reapply the spreader to the differential housing Remove the bearing cap Remove the differential To increase the amount of backlash reduce the shim thickness D Fig 4 and increase the shim thickness E Fig 11 by the same amount Reverse this step to decrease the backlash Remount the differential as before Release spreader tension Re check backlash ARB ___ 4 Installing the Air Locker 4 7 Modifying the Bearing Cap A clearance for the seal housing tube must be made in the bearing Cap 4 7 1 Marking the Tube Position With the Air Locker in place and less than 0 5mm of backlash an accurate measurement for the seal housing tube clearance can be made NOTE Take time and double check when taking your measurements as bearing caps are custom fitted to the axle housing and cannot be replaced With the seal housing tube pointing straight out measure the distance from a fixed position inside the differential housing to the center of the seal housing tube Fig 13 Record your findings and recheck for accuracy Remove the bearing cap from the ring gear side of the differential Remove the Air Locker from the differential housing Install the seal housing side bearing cap and hand tighten the bearing
27. ount specified for your vehicle Add the specified pre load amount to the measurement taken with the feeler gauge to determine a shim amount for E in Figure 11 PRE LOAD END FLOAT SHIM PACK Select suitable shims from the supplied shim kit to make up a shim pack of this thickness Remove the Air Locker and assemble the shim pack onto the seal housing spigot behind the master shim Figure 11 Spread the differential housing again Refer to section 2 6 NOTE Ifthe carrier is too difficult to install with the added shim pack then the spreader tension may need to be increased Do not spread the housing more than 0 50mm 0 020 Reinstall the Air Locker as before i e with only one bearing cap Release all spreader tension 4 6 Approximating the Backlash for Tube Position lf the backlash is not close enough to the specified amount the tube position cannot be accurately measured to modify the bearing cap for tube clearance This must be checked before hand ARB _ 4 Installing the Air Locker Set a depth indicator on one of the ring gear teeth as in figure 12 While supporting the pinion gear by holding the drive shaft 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 Make sure backlash is less than 0 5mm NOTE This backlash value is for the tube position o
28. the outside of the housing assemble the small O ring over the top of the short length of seal housing protruding through the bulkhead fitting While still 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 20 and screw it into the bulkhead body and lightly tighten Be sure to 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 20 CENTER COMPRESSION NUT x n un N p BULKHEAD BODY O RING DIFFERENTIAL HOUSING SEAL HOUSING TUBE TO SEAL HOUSING 4 Installing the Air Locker 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 Make sure the seal housing tube is all of the way into the center compression nut while you are tightening 4 12 Reinstalling the Axles Reinstall the axles and brake assembly according to the guidelines set forth in your vehicle manufacturers service manual Be careful not to damage the axle oil seals with the spline of the axle when inserting them The axles in the two following sections require special consideration at t
29. 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 _ ___ 5 Installing the Air System 5 2 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 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 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 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 Make sure the line does not contact sharp edges or abrasive surfaces that may damage the air line over time
30. ts 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 NOTE 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 ARB ___ 4 Installing the Air Locker 4 4 Drilling and Tapping the Bulkhead Port A port must be drilled and tapped through the differential housing to allow the seal housing tube through the housing to connect with the air line from the air compressor Mark a spot for the bulkhead port on the right hand seal housing side toward the top of the differential housing that is in an area that will be well clear of the ring gear the differential and any other obstructions that may snag the seal housing tube Cover the drive pinion and axle tube areas with a rag to protect them from metal filings Drill through the housing square to the outside surface using an 11 2mm 7 16 drill Fig 10 Tap the hole from the outside using a 4 NPT tapered pipe thread tap Remove any sharp edges from the hole that may chip off and fall into the housing Very carefully remove rags and inspect with a service light inside the housing to insure no metal filings are left behind ARB ___ 4 Inst
31. ved and re shimmed 4 9 1 Re Shimming the Backlash NOTE This step is only necessary when adjusting for incorrect backlash Reapply the spreader to the differential housing Remove the bearing caps Remove the differential To increase the amount of backlash reduce the shim thickness D Fig 5 and increase the shim thickness E Fig 11 by the same amount Reverse this step to decrease the backlash Remount the differential as before Release spreader tension Check backlash again as before 4 Installing the Air Locker 4 10 Profiling the Seal Housing Tube Without using sharp jagged tools such as pliers usually your hands are the best tool for this job bend the seal housing tube so that it closely follows the profile of the differential housing and protrudes through the bulkhead port in the differential housing Fig 19 Check that the contour of the tube will not interfere with the ring gear differential or the cover plate ARB 4 Installing the Air Locker 4 11 Setting Up the Bulkhead Fitting Apply thread sealant to the threads of the bulkhead body Screw the bulkhead body into the tapped hole and tighten Wipe the area clean of any excess thread sealant inside and outside of the housing Insert the free end of the seal housing tube into the bulkhead fitting until it protrudes approximately 8mm 5 16 through the other side From
32. vent dirt from entering the differential Position a fluid drain reservoir under the differential Remove the differential drain plug and completely drain all differential fluid Once drained reinstall the drain plug finger tight to prevent drips coming out of the housing and dust getting in 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 Remove the axles as indicated in your vehicle manufacturer s service manual In the case of IFS differential assemblies this will require the removal of the entire assembly first 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 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 t
33. witch es MUST be mounted and should never be allowed to simply dangle from the wiring loom during vehicle use 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 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 Switch cutout position s must be located in an area with a minimum of 50mm 2 of clearance behind the face of the cutout 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 recommenas that you apply the Air Locker Warning Sticker ARB part 210101 within close visual proximity of the switch location If no adequate position can be found on existing dashboard panels a surface mounted bracket Fig 25 may be purchased from your ARB Air Locker distributor to suit 1 2 or 3 switches ARB _ ___ 6 Mounting 8 Connecting the Electrical System REAR COMPRESSOR PORER AW 6 2 Wiring the Actuator System 6 2 1 Connection to an ARB Air Compressor When wiring the Air Locker actuator switch es and solenoid s to an ARB Air Compressor
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