Arb RD40 User Manual

INSTALLATION GUIDE RD40 GM, 9½”, 14 BOLT, 33 SPLINE Part No. 210240Revision Date 06/02/07Copyright © 2001 by ARB

2 Removing the Existing Differential 8 2.6 Removing the Differential Carrier  Loosen the adjuster nuts.  Remove the bearing caps from

3 Installing the Air Locker 9 3.1 Installing the Carrier Bearings  With the Air Locker well supported in an arbor press, apply a thin film

3 Installing the Air Locker 10 3.2 Mounting the Ring Gear  Apply a thin film of high-pressure grease to the ring gear shoulder of the Air

3 Installing the Air Locker 11 3.3 Drilling and Tapping the Bulkhead Port A port must be drilled and tapped through the differential housi

3 Installing the Air Locker 12 3.4 Assembling the Differential Carrier  Place the bearing cups over the bearing cones.  Slide the seal ho

3 Installing the Air Locker 13  While supporting the pinion gear by holding the drive shaft, rotate the differential in both directions while

3 Installing the Air Locker 14  Install the seal housing side bearing cap and hand-tighten the bearing cap bolts. NOTE : It is very import

3 Installing the Air Locker 15 3.7 Modifying the Bearing Cap 3.7.1 Drilling the Bearing Cap  Hold the bearing cap steady for drilling i

3 Installing the Air Locker 16 Figure 10. 3.7.2 Notching the Bearing Cap  Use a soft jawed vise clamp to hold the bearing c

3 Installing the Air Locker 17 3.8 Final Air Locker Assembly  Remove the seal housing and clean all parts of the differential assembly. I

No liability is assumed for damages resulting in the use of the information contained herein. ARB Air Locker Locking Differentials and Air Lo

3 Installing the Air Locker 18 IMPORTANT: It is critical to set up bearing pre-load when a differential is installed. Improper pre-load will re

3 Installing the Air Locker 19 3.10 Profiling the Seal Housing Tube  Without using sharp, jagged tools such as pliers (usually your hands

3 Installing the Air Locker 20  From the outside of the housing, assemble the small O-ring over the top of the short length of seal housing tu

3 Installing the Air Locker 21  Again check that no part of the seal housing tube comes in contact with the moving differential components. Le

4 Installing the Air System 22 4.1 Mounting the Solenoid 4.1.1 Connection to an ARB Air Compressor (Fig.15.)  Remove one of the 1/8”

4 Installing the Air System 23 4.1.2 Connection to an Alternate Air Source For ease of installation, quality of air supply, and a high lev

4 Installing the Air System 24 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 25 NOTE : To remove the air line from the push-in fitting; while holding the flange of the fitting out, push th

4 Installing the Air System 26 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 27 5.1 Mounting the Actuator Switch(es) Air Locker actuator switch(es) can be easily pan

Table of Contents: 1 1 Introduction 31.1 Pre-Installation Preparation 1.21.3 Tool-Kit Recommendations 1.4 2 Removing the Existing

5 Mounting & Connecting the Electrical System 28 Figure 17. 5.2 Wiring the Actuator System 5.2.1 Connection

5 Mounting & Connecting the Electrical System 29 UP Figure 18. Figure 19. SWITCHTERMINALIDENTIFICATION ARB

5 Mounting & Connecting the Electrical System 30 5.2.2 Connection to an Alternate Air Source When connecting the actuation switch to a

5 Mounting & Connecting the Electrical System 31 5.2.2.2 Dual Air Locker System  If two Air Lockers are to be installed in the syste

6 Testing & Final Assembly 32 6.1 Leak Testing  With the vehicle parked and the engine off, turn the compressor on and wait until the

6 Testing & Final Assembly 33  Turn the ignition to the ‘ON’ position (leaving the motor off). The large illuminating symbol on the Air L

6 Testing & Final Assembly 34 6.4 Post-Installation Check List Now that the Air Locker installation has been completed, ARB recommends

7 Parts List 35 7.1 Exploded Assembly Diagram (See itemized parts list overleaf) Figure 22.

7 Parts List 36 7.2 Itemized Parts List (See exploded diagram figure 22.) AIR LOCKER MODEL No. : RD40 ITEM # QTY DESCRIPTION

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

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

2 Removing the Existing Differential 5 2.1 Vehicle Support  Safely secure the vehicle on a hoist. We recommend supporting the vehicle

2 Removing the Existing Differential 6  Remove the wheels and brake assembly according to your vehicle’s service manual.  Remove the cro

2 Removing the Existing Differential 7 2.5 Checking the Current Backlash Amount IMPORTANT: This step is a precautionary measure recom