Arb RD135 Manuel d'utilisateur

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Page 1 - INSTALLATION GUIDE

INSTALLATION GUIDE RD135 Part No. 2102135Revision Date 21/01/2008Copyright © 2008 by ARB Corporatio

Page 2 - ARB 4x4 ACCESSORIES

2 Removing the Existing Differential 8 2.6 Removing the differential carrier  Remove the adjuster nut locking tabs.  Remove the bearing cap

Page 3

3 Installing the Air Locker 9 3.1 Mounting the Ring Gear  Remove the bolts that hold the ring gear in place. IMPORTANT: Two different bolt

Page 4

3 Installing the Air Locker 10 NOTE : NEVER HEAT GEARS WITH A FLAME! This could damage the hardened surface of the gear and result in premat

Page 5 -  symbols as

3 Installing the Air Locker 11 3.2 Installing the Carrier Bearings NOTE : The Air Locker has been designed to employ higher rated 50mm car

Page 6 - Supplies

3 Installing the Air Locker 12 3.3 Drilling and Tapping the Bulkhead Port An air line port must be drilled and tapped through the differenti

Page 7 - Differential Fluid Drain

3 Installing the Air Locker 13 3.4 Final Air Locker Assembly  Clean all parts of the differential assembly, paying particular attention to

Page 8 - Marking the Bearing Caps

3 Installing the Air Locker 14 3.5 Checking the Backlash  Set a depth indicator on one of the ring gear teeth. (Fig.7.)  While supporting

Page 9

3 Installing the Air Locker 15 3.6 Installing the Seal Housing  Make sure the grooves and airway of the seal housing are clean and free fr

Page 10 -  Remove the adjuster nuts

3 Installing the Air Locker 16  Install the spring clip by first hooking both ends of the clip into the small aligned cutouts of the seal housi

Page 11 - IMPORTANT:

3 Installing the Air Locker 17 Figure 10. NOTE : Use an automotive brake line tubing cutter to cut the seal housing tube,

Page 12 - Figure 4

No liability is assumed for damages resulting in the use of the information contained herein. ARB AIR LOCKER Locking Differentials and AIR LOCKER a

Page 13 -

3 Installing the Air Locker 18 Figure 11. NOTE : Excessive tightening of the center compression nut is not necessary to fo

Page 14 - Figure 6

3 Installing the Air Locker 19 3.8 Profiling the Seal Housing Tube  With the seal housing tube now firmly secured into the bulkhead fitting

Page 15 - Final Air Locker Assembly

3 Installing the Air Locker 20 Figure 14. IMPORTANT: In order for the seal housing to float and self center on the bearing jo

Page 16 - Checking the Backlash

3 Installing the Air Locker 21 3.9 Bench Testing the Air Locker  To test the Air Locker, when 620kPa [90 PSI] shop air is applied to the sea

Page 17 - Installing the Seal Housing

3 Installing the Air Locker 22 3.10 Reinstalling Differential and Axles  Replace the paper gasket on the axle housing flange.  Reinstall t

Page 18

4 Installing the Air System 23 4.1 Mounting the Solenoid 4.1.1 Connection to an ARB Air Compressor (Fig.16.)  Remove one of the 1/8” BS

Page 19 - Figure 10

4 Installing the Air System 24 4.1.2 Connection to an Alternate Air Source For ease of installation, quality of air supply, and a high level

Page 20 - Figure 11

4 Installing the Air System 25 4.2 Running and Securing the Air Line The path taken by the air line from your air source (i.e., compressor)

Page 21

4 Installing the Air System 26 NOTE : To remove the air line from the push-in fitting; pull outward on the flange of the fitting, push the ai

Page 22

4 Installing the Air System 27 HINT : If the support tube is too difficult to insert, place the end of the air line into a cup of boiled wat

Page 23 - Bench Testing the Air Locker

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

Page 24

5 Mounting & Connecting the Electrical System 28 5.1 Mounting the Actuator Switch(es) Air Locker actuator switch(es) can be easily pane

Page 25 - Air Compressor

5 Mounting & Connecting the Electrical System 29 5.2 Wiring the Actuator System 5.2.1 Connection to an ARB AIR COMPRESSOR When wiri

Page 26 - IMPORTANT :

5 Mounting & Connecting the Electrical System 30 Figure 20. 5.2.2 Connection to an Alternate Air Source When connecting the

Page 27

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 system

Page 28

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 a

Page 29

6 Testing & Final Assembly 33  Turn the compressor (or alternate air source) on to charge the air supply up to its maximum pressure.  Rota

Page 30 - Figure 18

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

Page 31 - Wiring the Actuator System

7 Parts List 35 7.1 Exploded Assembly Diagram (See itemized parts list overleaf) Figure 23.

Page 32 - IDENTIFICATION

7 Parts List 36 7.2 Itemized Parts List (See exploded diagram Figure 23.) AIR LOCKER MODEL No. : RD135 ITEM # QTY DESCRIPTION

Page 34 - Leak Testing

3 IMPORTANT : BEFORE ATTEMPTING TO DISMANTLE YOUR VEHICLE FOR THIS INSTALLATION, PLEASE READ THIS INSTALLATION GUIDE IN ITS ENTIRETY, AS WELL AS

Page 35 - Filling the Differential

2 Removing the Existing Differential 4 1.2 Tool-Kit Recommendations Below is a list of tools and supplies you may need to complete this ins

Page 36

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

Page 37 - Exploded Assembly Diagram

2 Removing the Existing Differential 6 2.4 Marking the Bearing Caps  Using a small pointed center punch, gently mark the bearing caps in a

Page 38 - Itemized Parts List

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

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