Arb RD101 User Manual

INSTALLATION GUIDE RD101DANA 30, 27 SPLINE, 3.54 & DN Part No. 2102101Revision Date 08/04/03Copyright © 200

2 Removing the Existing Differential 8 2.4 Marking the Bearing Caps c Using a pointed center punch, gently mark the bearing caps in a way t

2 Removing the Existing Differential 9 2.5 Checking the Current Backlash Amount IMPORTANT: This step is a precautionary measure recommend

2 Removing the Existing Differential 10 2.6 Removing the Differential Center 2.6.1 A Cast Aluminum Housings IMPORTANT: YOU MUST N

2 Removing the Existing Differential 11 HINT : Be sure not to mix up the left and right hand bearing cups. Later it will be necessary to k

3 Installing the Air Locker 12 3.1 B Insuring Adequate Oil Drainage IMPORTANT: Some Salisbury axles were manufactured with poor oil d

3 Installing the Air Locker 13 NOTE : Make sure any grinding dust, filings or drill chips left behind by cutting the drainage slots is comp

3 Installing the Air Locker 14 3.3 Approximate Backlash Shimming In order to reproduce a similar pre-load and ring and pinion backlash in yo

3 Installing the Air Locker 15 c Assemble the new bearing cup and master shim (supplied with your Air Locker kit) onto the right-hand side of t

3 Installing the Air Locker 16 c Select shims from the shim kit supplied with your Air Locker to make the thickness ‘B’ as determined above. c

3 Installing the Air Locker 17 3.5 Drilling and Tapping the Bulkhead Port An airline port must be drilled and tapped through the different

No liability is assumed for damages resulting in the use of the information contained herein. ARB Air Locker Air Operated Locking Differentia

3 Installing the Air Locker 18 3.5.2 B Port Location on the Live Axle Housing c Mark a spot on the top of the outside shell of the differ

3 Installing the Air Locker 19 3.6 Assembling the Seal Housing Figure 13. c Make sure the grooves and airway of the s

3 Installing the Air Locker 20 3.7 Pre-Load Shimming In order to pre-load the tapered roller bearings in your Air Locker, measurements need

3 Installing the Air Locker 21 Figure 15. c Consult your vehicle manufacturer’s service manual to determine the carrier bearing

3 Installing the Air Locker 22 Figure 16. c Tap the factory shim into place between the seal housing and the aluminum housing with

3 Installing the Air Locker 23 3.7.2 B Pre-Loading a Live Axle Housing c Insert and hold the Air Locker into the differential housing.

3 Installing the Air Locker 24 c Install the shim pack ‘D’ between the master shim and the seal housing as shown in Figure 13. c Spread the dif

3 Installing the Air Locker 25 3.8 Reinstalling the Bearing Caps IMPORTANT: The Air Locker master shim must be assembled between the ste

3 Installing the Air Locker 26 3.9 Checking the Backlash c Set a depth indicator on one of the ring gear teeth as in Figure 21. c While s

3 Installing the Air Locker 27 3.9.1 Re-Shimming the Backlash NOTE : This step is only necessary when adjusting for incorrect backlash.

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

3 Installing the Air Locker 28 Figure 22. NOTE : Excessive tightening of the center compression nut is not necessary to f

3 Installing the Air Locker 29 3.11 Profiling the Seal Housing Tube c Completely remove the differential spreader (if applicable). c Witho

4 Installing the Air System 30 4.1 Mounting the Solenoid 4.1.1 Connection to an ARB Air Compressor (Fig.24.) c Remove one of the 1/8”

4 Installing the Air System 31 4.1.2 Connection to an Alternate Air Source For ease of installation, quality of air supply, and a high le

4 Installing the Air System 32 4.2 Running and Securing the Air Line The path taken by the air line from your air source (i.e., compressor

4 Installing the Air System 33 c To attach the air line to the push-in fitting of the solenoid; insert the line firmly into the fitting, pull

4 Installing the Air System 34 HINT : If the support tube is too difficult to insert, place the end of the air line into a cup of boiled w

5 Mounting & Connecting the Electrical System 35 5.1 Mounting the Actuator Switch(es) Air Locker actuator switch(es) can be easily pan

5 Mounting & Connecting the Electrical System 36 Figure 26. 5.2 Wiring the Actuator System 5.2.1 Connectio

5 Mounting & Connecting the Electrical System 37 UP Figure 27. Figure 28. SWITCHTERMINALIDENTIFICATION ARB

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5 Mounting & Connecting the Electrical System 38 5.2.2 Connection to an Alternate Air Source When connecting the actuation switch to a

5 Mounting & Connecting the Electrical System 39 5.2.2.2 Dual Air Locker System c If two Air Lockers are to be installed in the syste

6 Testing & Final Assembly 40 6.1 Leak Testing c With the vehicle parked and the engine off, turn the compressor on and wait until the

6 Testing & Final Assembly 41 6.3 Testing the Air Locker Actuation To test that your air system, electrical system, and your Air Locke

6 Testing & Final Assembly 42 6.5 Post-Installation Check List Now that the Air Locker installation has been completed, ARB recommends

7 Parts List 43 7.1 Exploded Assembly Diagram (See itemized parts list overleaf) Figure 31.

7 Parts List 44 7.2 Itemized Parts List (See exploded diagram figure 31.) AIR LOCKER MODEL No. : RD101 ITEM # QTY DESCRIPTION

1 Introduction 3 IMPORTANT : BEFORE ATTEMPTING TO DISMANTLE YOUR VEHICLE FOR THIS INSTALLATION, PLEASE READ THIS INSTALLATION GUIDE IN ITS E

1 Introduction 4 1.2 Tool-Kit Recommendations Below is a list of tools and supplies you may need to complete this installation. Requireme

1 Introduction 5 1.3 Assembly Type Identification IMPORTANT: Sections 2 and 3 of this installation guide have been written to accommodat

2 Removing the Existing Differential 6 2.1 Vehicle Support c Safely secure the vehicle on a hoist. We recommend supporting the vehicle on a

2 Removing the Existing Differential 7 2.3 Disconnecting the Axles 2.3.1 A IFS CV Shafts c Remove the wheels, and brakes according to