INSTALLATION GUIDE RD90 TOYOYA 7.5”, IFS Part No. 210290Revision 06/07/05Copyright © 2002 by ARB Corporation Lim
2 Removing the Existing Differential 8 2.4 A B Checking the Current Backlash Amount IMPORTANT: This step is a precautionary measure r
2 Removing the Existing Differential 9 2.4.2 B Backlash for Clamshell Housing c Set a long series lever type dial indicator on one of the
2 Removing the Existing Differential 10 2.5 A B Removing the Differential Center c Remove the floating shaft (or ADD unit if present) fr
3 Installing the Air Locker 11 3.1 A B Approximate Backlash Shimming In order to reproduce a similar preload and ring and pinion backlas
3 Installing the Air Locker 12 c Using a caliper or similarly accurate measurement method (i.e., able to take accurate measurements within 0.0
3 Installing the Air Locker 13 3.2 A B Calculation & Selection of Backlash Shims Ideally, the measurement you recorded as ‘C’ from t
3 Installing the Air Locker 14 3.3 A B Mounting the Ring Gear c Apply a thin film of high pressure grease to the ring gear shoulder of t
3 Installing the Air Locker 15 3.4 A B Installing the Carrier Bearings c Apply a thin film of high pressure grease to both bearing journ
3 Installing the Air Locker 16 3.5 A B Preload Shim Measurement In order to preload the tapered roller bearings in your Air Locker, measu
3 Installing the Air Locker 17 3.5.2 B Clamshell Housing Preload c Assemble the shim pack determined earlier as ‘D’ (Fig.7.) into the b
No liability is assumed for damages resulting in the use of the information contained herein. ARB AIR LOCKER Locking Differentials and AIR LOCKER ar
3 Installing the Air Locker 18 NOTE : The preload gap should be the same when measured all the way around the housing. If this is not true,
3 Installing the Air Locker 19 3.7 A B Drilling & Tapping the Bulkhead Port A port must be drilled and tapped through the different
3 Installing the Air Locker 20 HINT : Use the location of the oil vent hole to gauge where the position should be. Figure 12.
3 Installing the Air Locker 21 NOTE : The drawing in Figure 13. shows a cross section of the bulkhead body installed into the clamshell. T
3 Installing the Air Locker 22 c Make sure the seal housing tube and the grooves of the seal housing are clean and free from any contaminants (e
3 Installing the Air Locker 23 3.9.2 B Clamshell Housing Installation c Assemble the shim pack ‘E’ (Fig.9.) into the bearing bore of the s
3 Installing the Air Locker 24 3.10 A B Setting Up the Bulkhead Fitting c Insert the end of the seal housing tube into the bulkhead fitt
3 Installing the Air Locker 25 3.11 A B Final Assembly The seal housing tube needs to be carefully bent so that it will stay clear of
3 Installing the Air Locker 26 Figure 18. 3.11.2 B Clamshell Housing Tube Profile c Press the seal housing tube flat to t
3 Installing the Air Locker 27 3.12 A B Checking the Backlash c Refer to your vehicle manufacturer’s service manual for the specified
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 c To decrease the amount of backlash, reduce the shim thickness ‘D’ (Fig.7.) and increase the shim thickness ‘E’
3 Installing the Air Locker 29 3.12.4 B Re-Shimming the Backlash NOTE : This step is only necessary when adjusting for incorrect backl
3 Installing the Air Locker 30 3.13 A B Bench Testing the Air Locker c To bench test the Air Locker; when 620kPa [90 PSI] shop air is ap
3 Installing the Air Locker 31 3.14 A B Reinstalling the Differential Assembly c Reassemble the differential assembly according to you
4 Installing the Air System 32 4.1 Mounting the Solenoid 4.1.1 Connection to an ARB Air Compressor (Fig.23.) c Remove one of the 1/8”
4 Installing the Air System 33 4.1.2 Connection to an Alternate Air Source For ease of installation, quality of air supply, and a high leve
4 Installing the Air System 34 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 35 4.3 Connection to the Bulkhead Fitting c Trim the air line to length using a sharp knife. c Insert the suppor
5 Mounting & Connecting the Electrical System 36 5.1 Mounting the Actuator Switch(es) Air Locker actuator switch(es) can be easily pane
5 Mounting & Connecting the Electrical System 37 5.2 Wiring the Actuator System 5.2.1 Connection to an ARB Air Compressor When wir
5 Mounting & Connecting the Electrical System 38 Figure 28. 5.2.2 Connection to an Alternate Air Source When connecting th
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 a
6 Testing & Final Assembly 41 c Turn the Air Locker switch to the ‘ON’ position. The illuminated symbol on the switch cover should light up
6 Testing & Final Assembly 42 6.5 Post-Installation Check List Now that the Air Locker installation has been completed, ARB recommends t
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 Fig.31. ) AIR LOCKER MODEL No. : RD90 ITEM # QTY DESCRIPTION PA
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
1 Introduction 5 1.3 Assembly Type Identification IMPORTANT: Sections 2 and 3 of this installation guide have been written to accommodate
2 Removing the Existing Differential 6 2.1 A B Vehicle Support c Safely secure the vehicle on a hoist. We recommend supporting the vehi
2 Removing the Existing Differential 7 2.3.1 A Marking the Bearing Caps c Secure the differential assembly to a work bench. c Completely
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