Arb RD109 Manuel d'utilisateur

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Page 1 - INSTALLATION GUIDE

INSTALLATION GUIDE RD109DANA 44, 35 SPLINE, 3.92 & UP Part No. 2102109Revision Date 25/03/08Copyright © 200

Page 2 - ARB 4x4 ACCESSORIES

2 Removing the Existing Differential 8 2.6 Removing the Differential Center IMPORTANT: YOU MUST SPREAD THE HOUSING ON CAST IRON MODELS

Page 3 - Table of Contents:

2 Removing the Existing Differential 9 NOTE : The differential center is heavy and quite difficult to handle when covered in oil. Take care

Page 4

3 Installing the Air Locker 10 3.1 Insuring Adequate Oil Drainage IMPORTANT: Some Salisbury axles were manufactured with poor oil drai

Page 5 - Pre-Installation Preparation

3 Installing the Air Locker 11 NOTE : Make sure any grinding dust, filings or drill chips left behind by cutting the drainage slots is comp

Page 6 - Supplies

3 Installing the Air Locker 12 3.3 Approximate Backlash Shimming In order to reproduce a similar pre-load and ring and pinion backlash in yo

Page 7 - Differential Fluid Drain

3 Installing the Air Locker 13 NOTE : Be sure to measure using the bearing cup that originally came off of the right-hand side.  Assemble

Page 8 - Marking the Bearing Caps

3 Installing the Air Locker 14 The thickness of the shim pack ‘B’ should make the distance ‘C’ on the Air Locker closely match the distance ‘A’

Page 9

3 Installing the Air Locker 15 3.4 Mounting the Ring Gear IMPORTANT: Dana 44 ring gears may use either 3/8”, 7/16”, or 1/2” bolts. For 7/

Page 10 - Figure 3

3 Installing the Air Locker 16 3.5 Drilling and Tapping the Bulkhead Port An airline port must be drilled and tapped through the different

Page 11

3 Installing the Air Locker 17 3.6 Assembling the Seal Housing Figure 9.  Make sure the grooves and airway of the se

Page 12 - IMPORTANT:

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

Page 13 - Figure 5

3 Installing the Air Locker 18  Carefully install the seal housing (ARB master shim towards the center) by sliding it all of the way onto the

Page 14

3 Installing the Air Locker 19 Figure 11.  Consult your vehicle manufacturer’s service manual to determine the carrier bearing pre

Page 15

3 Installing the Air Locker 20 Figure 12.  Release all spreader tension.  Check that some backlash can be felt between the rin

Page 16 - A – B – C =

3 Installing the Air Locker 21 3.8 Reinstalling the Bearing Caps IMPORTANT: The ARB master shim must be assembled between the stepped si

Page 17 - Mounting the Ring Gear

3 Installing the Air Locker 22 3.9 Checking the Backlash  Set a depth indicator on one of the ring gear teeth as in Figure 14.  While s

Page 18 - Figure 8

3 Installing the Air Locker 23 3.9.1 Re-Shimming the Backlash NOTE : This step is only necessary when adjusting for incorrect backlash.

Page 19 - Assembling the Seal Housing

3 Installing the Air Locker 24 Figure 15. NOTE : Excessive tightening of the center compression nut is not necessary to f

Page 20 - DANA 44 SETUP:

3 Installing the Air Locker 25 3.11 Profiling the Seal Housing Tube  Completely remove the differential spreader.  Without using sharp,

Page 21 - Figure 11

4 Installing the Air System 26 4.1 Mounting the Solenoid 4.1.1 Connection to an ARB Air Compressor (Fig.17.)  Remove one of the 1/8”

Page 22 - Figure 12

4 Installing the Air System 27 4.1.2 Connection to an Alternate Air Source For ease of installation, quality of air supply, and a high le

Page 23 - Reinstalling the Bearing Caps

Table of Contents: 1 1 Introduction 31.1 Pre-Installation Preparation 31.2 Tool-Kit Recommendations 4 2 Removing the Existing Differ

Page 24 - Checking the Backlash

4 Installing the Air System 28 4.2 Running and Securing the Air Line The path taken by the air line from your air source (i.e., compressor

Page 25 - Re-Shimming the Backlash

4 Installing the Air System 29  To attach the air line to the push-in fitting of the solenoid; insert the line firmly into the fitting, pull

Page 26 - Figure 15

4 Installing the Air System 30 HINT : If the support tube is too difficult to insert, place the end of the air line into a cup of boiled w

Page 27 - Figure 16

5 Mounting & Connecting the Electrical System 31 5.1 Mounting the Actuator Switch(es) Air Locker actuator switch(es) can be easily pan

Page 28 - Mounting the Solenoid

5 Mounting & Connecting the Electrical System 32 Figure 19. 5.2 Wiring the Actuator System 5.2.1 Connectio

Page 29 - IMPORTANT :

5 Mounting & Connecting the Electrical System 33 UP Figure 20. Figure 21. SWITCHTERMINALIDENTIFICATION ARB

Page 30

5 Mounting & Connecting the Electrical System 34 5.2.2 Connection to an Alternate Air Source When connecting the actuation switch to a

Page 31 - Figure 18

5 Mounting & Connecting the Electrical System 35 5.2.2.2 Dual Air Locker System  If two Air Lockers are to be installed in the syste

Page 32

6 Testing & Final Assembly 36 6.1 Leak Testing  With the vehicle parked and the engine off, turn the compressor on and wait until the

Page 33

6 Testing & Final Assembly 37 6.3 Testing the Air Locker Actuation To test that your air system, electrical system, and your Air Locke

Page 35

6 Testing & Final Assembly 38 6.5 Post-Installation Check List Now that the Air Locker installation has been completed, ARB recommends

Page 36 - Single Air Locker System

7 Parts List 39 7.1 Exploded Assembly Diagram (See itemized parts list overleaf) Figure 24.

Page 37 - Dual Air Locker System

7 Parts List 40 7.2 Itemized Parts List (See exploded diagram figure 24.) AIR LOCKER MODEL No. : RD109 ITEM # QTY DESCRIPTIO

Page 38 - Reinstalling the Axles

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

Page 39

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

Page 40

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

Page 41 - Exploded Assembly Diagram

2 Removing the Existing Differential 6 2.3 Disconnecting the Axles IMPORTANT : Collision damage or heavy off-road use of your vehicle in

Page 42 - Itemized Parts List

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

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