ARB RD203, Installation Manual

Page 1: ...ISUZU IFS 17 SPLINE AIR OPERATED LOCKING DIFFERENTIAL INSTALLATION GUIDE ...

Page 2: ...r product names used herein are for identification purposes only and may be trademarks of their respective owners ARB 4x4 ACCESSORIES Corporate Head Office 42 44 Garden St Tel 61 3 9761 6622 Kilsyth Victoria Fax 61 3 9761 6807 AUSTRALIA 3137 Australian enquires sales arb com au North and South American enquires sales arbusa com Other international enquires exports arb com au www arb com au ...

Page 3: ...4 4 4 Assembling the Differential Carrier 16 4 5 Modifying the Bearing Cap 18 4 6 Final Air Locker Assembly 19 4 7 Final Backlash Checking 20 4 8 Profiling the Seal Housing Tube 21 4 9 Setting up the Bulkhead Fitting 23 4 10 Bench Testing the Air Locker 24 4 11 Reinstalling the Axles 25 5 Installing the Air System 26 5 1 Mounting the Solenoid 26 5 2 Running Securing the Air Line 28 5 3 Connection ...

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Page 5: ...hough your ARB Air Locker comes complete with all the step by step instructions you will need to supplement your vehicle manufacturer s service manual and install your new differential ARB recommends that you have your Air Locker installed by a trained professional Many ARB distributors around the world have been fully instructed in Air Locker installations by ARB and have gained a wealth of exper...

Page 6: ...ue wrench See vehicle service manual for required torque range A lubricant drain reservoir Suitable measuring tools to measure a differential for pre load and or backlash shimming See Section 3 Bench Measurement An 11 2mm 7 16 drill and NPT tap for bulkhead fitting installation An automotive bearing puller e g ARB Bearing Puller 0770001 or a differential carrier bearing puller A bearing press or a...

Page 7: ... finger tight to prevent drips coming out of the housing and dust getting in HINT This is a good time to check for metal particles in your oil and in the bottom of the housing which may indicate a worn bearing or differential component 2 3 Removal of the Axles and Differential Remove the front wheels from the vehicle Disconnect the drive shaft from the flange of the differential Remove the front a...

Page 8: ...mark the bearing caps in a way that will enable you to know which cap is LEFT and which cap is RIGHT which way is UP and which way is DOWN Fig 1 Mark the right hand cap in a similar way HINT Many installers choose to make one punch mark on the left hand side of the left hand bearing cap and one similar punch mark on the housing at close proximity to the cap mark The right hand side is then designa...

Page 9: ...manual Measurements found to be outside of your service manual recommendations may indicate the need to deviate from those settings in order to achieve quiet running with a good contact mark Refer to your vehicle service manual or your local authorized ARB installer for more information Set a depth indicator on one of the ring gear teeth as in figure 2 While supporting the pinion gear by holding t...

Page 10: ...sed running noise and ultimately ring and pinion gear damage Unbolt and remove the bearing caps Setup the differential spreader and a dial indicator and carefully spread the differential housing Fig 3 just enough to remove the differential carrier Refer to your vehicle s service manual NOTE Never spread the housing more than 0 5mm 0 020 Once the housing has been adequately spread the differential ...

Page 11: ... differential to a workbench Remove the bolts that hold the ring gear in place Using a plastic or copper hammer tap in a circle around the ring gear to separate it from the differential carrier Remove the original tapered roller bearings and shims from the differential carrier using a bearing puller Fig 4 NOTE Keep the shims separated so that they can be identified as to which end of the different...

Page 12: ...o the ring gear mounting face shown as A in Figure 5 and record this measurement as A Measure the thickness of the shim pack removed from the case side of the differential carrier shown as B in Figure 5 and record this measurement as B Measure the distance from the Air Locker bearing shoulder to the ring gear mounting face shown as C in Figure 6 and record this measurement as C Figure 5 ...

Page 13: ... the measurements taken into the following equation A B C D HINT If your calculations are correct then the following equation will also be true A B C D ZERO To make a shim pack to match the measurement you calculated as D you can select shims from the shim kit supplied with your Air Locker use a universal shim kit available from most drive train specialists NOTE Never re use any shims that are dam...

Page 14: ... Press one of the tapered roller bearing cones onto the bearing journal of the differential carrier until the bearing seats firmly against the bearing journal shoulder Figure 7 NOTE Never re use any bearings that are damaged or worn Invert the Air Locker and apply a thin film of high pressure grease to the ring gear side bearing journal Press an original bearing cone onto the Air Locker bearing jo...

Page 15: ...TH A FLAME This could damage the hardened surface of the gear and result in premature wear or failure Dry the ring gear with compressed air if wet paying particular attention to the threaded holes Install the ring gear onto the Air Locker by aligning the holes in the flange with the tapped holes in the ring gear then gently tapping it around in a circle with a plastic or copper hammer NOTE Avoid u...

Page 16: ...or the bulkhead port on the left hand seal housing side toward the top of the differential housing that is in an area that will be well clear of the ring gear the differential and any other obstructions that may snag the seal housing tube Fig 8 Aluminium Axle Case Mark a spot for the bulkhead port on the lower left corner opposite the oil fill plug of the aluminium axle case approximately 20 25mm ...

Page 17: ...he housing square to the outside surface using an 11 2mm 7 16 drill Tap the hole from the outside using a NPT tapered pipe thread tap Remove any sharp edges from the hole that may chip off and fall into the housing Very carefully remove rags and inspect with a service light inside the housing to ensure no metal filings are left behind ...

Page 18: ...ter nut NOTE A twisting motion i e a slight rotation while pressing the seal housing on will allow the O rings to engage gently and prevent them from twisting Twisted O rings will result in pre mature O ring wear and oil contamination in the air system due to the helical shape formed by the O ring mould line By holding all assembled components as shown in Figure 10 In place at each end except the ...

Page 19: ...auge Consult your vehicle manufacturer s service manual to determine the carrier bearing pre load amount specified for your vehicle Add the specified pre load amount to the measurement taken with the feeler gauge to determine a shim amount for E in Figure 10 PRE LOAD END FLOAT SHIM PACK Select suitable shims from the supplied shim kit to make up a shim pack of this thickness ...

Page 20: ...ocation on the bearing cap off center as shown that would allow a 6 35mm hole to be drilled with 1mm 0 039 clearance from the edge of the hole and the machined bearing recess Fig 11 Figure 11 NOTE Take time and double check when taking your measurements as bearing caps are custom fitted to the diff housing and cannot be replaced Hold the bearing cap steady for drilling in a soft jawed vice clamp N...

Page 21: ...old the shims seal housing and tapered roller bearing cups in place and insert and hold the Air Locker into the differential housing NOTE If the carrier is too difficult to install with the added shim pack then the spreader tension may need to be increased Do not spread the housing more than 0 50mm 0 020 Relieve all tension on the housing spreader Install the bearing caps in their respective sides...

Page 22: ... to your vehicle service manual for the specified maximum and minimum amounts of backlash If the backlash is not within the specifications then the differential will have to be removed and re shimmed 4 7 1 Re Shimming the Backlash NOTE This step is only necessary when adjusting for incorrect backlash Reapply the spreader to the differential housing Remove the bearing caps Remove the differential T...

Page 23: ...ds are the best tool for this job bend the seal housing tube so that it closely follows the profile of the differential housing and protrudes through the bulkhead port in the differential housing Fig 14 15 Figure 15 Figure 14 NOTE It is also a good idea to keep the tube away from the bearing caps or any other part of the differential casting as any contact due to vibration or shock may wear the tu...

Page 24: ...mediately where it protrudes through the bearing housing and then another sharp bend upwards at approximately 25mm from the centre line Fig 16 The tube can be adjusted more accurately by positioning the aluminium case in place Fig 17 When the tube profile is finalized apply gasket sealant on the sealing face of the axle case and finger tighten it to the differential housing Figure 16 Figure 17 ...

Page 25: ...ess thread sealant inside and outside of the housing Insert the free end of the seal housing tube into the bulkhead fitting until it protrudes approximately 8mm 5 16 through the other side From the outside of the housing assemble the small O ring over the top of the short length of seal housing tube protruding through the bulkhead fitting While holding the seal housing tube into the bulkhead fitti...

Page 26: ...sting the Air Locker To test the Air Locker when 620kPa 90 PSI shop air is applied to the seal housing tube the Air Locker should engage Check all fittings and the seal housing for air leaks Rotate the differential carrier by turning the pinion flange whilst applying air pressure NOTE An accurate way to test for air leaks is to fit a shut off valve to an air pressure gauge ARB part 0770005 shown i...

Page 27: ... been damaged during installation 4 11 Reinstalling the Axles Reinstall the differential housing into the axle case using gasket sealant where necessary Reinstall the front axle assembly according to your vehicle manufacturer s service manual NOTE Be careful not to damage the axle oil seals with the spline of the axle Reconnect the drive shaft onto the flange of the differential Reassemble the bra...

Page 28: ...the inlet port side of the solenoid stamped with a 1 onto the nipple and hand tighten it The solenoid should be rotated into a position that does not obstruct any other ports on the compressor tank NOTE The solenoid exhausts compressed air through the center of the black retaining cap when the Air Locker is disengaged Make sure this orifice cannot be obstructed Apply Teflon paste to the threads of...

Page 29: ...at you have the necessary capacity is to make sure you can engage disengage and then re engage your Air Locker s without the air source having to regenerate e g without the compressor turning on to refill the tank Must supply clean air free of rust dirt water or other foreign matter Must match the 1 8 BSP porting of the Air Locker solenoid Mount solenoid within close proximity of the air supply an...

Page 30: ...p edges or abrasive surfaces that may damage the air line over time Do not run the air line around tight bends that may kink the air line and restrict or block the air flow Keep the air line well away from your vehicle s exhaust components Air lines will melt if subjected to extreme heat Do not run more air line than necessary Excess line volume created when coiling the left over hose using unusua...

Page 31: ...way to the end Figure 21 HINT If the tube is too difficult to push on place the end of the air line into a cup of boiled water to soften the tubing Screw on the outer compression nut and tighten while supporting the center compression nut with a 3 8 spanner The airline is now attached to the center compression nut NOTE The outer compression nut will tighten against a stop Over tightening will not ...

Page 32: ...e wiring loom during vehicle use Switch es should be within easy reach of the driver Ideally any Air Locker switch should be able to be operated without physical effort or distraction to the driver Switch es should be mounted within the line of sight of the driver so that switch position ON or OFF can be visually determined by the rocker position and the illumination state The position of the swit...

Page 33: ...ng the Electrical System 31 NOTE If no adequate position can be found on existing dashboard panels a surface mounted bracket Fig 22 may be purchased from your ARB Air Locker distributor to suit 1 2 or 3 switches Figure 22 ...

Page 34: ...hen wiring the Air Locker actuator switch es and solenoid s to an ARB Air Compressor all connections can easily be set up directly from the supplied wiring loom Fig 23 NOTE 180409 model loom shown for reference only Refer to your ARB Air Compressor Installation Guide for details on configuring your installation Figure 23 ...

Page 35: ... in the vehicle 6 2 2 1 Single Air Locker System If only one Air Locker is to be installed in the system the switch and solenoid should be wired according to figure 25 regardless of whether the Air Locker has been installed in the front or rear axle of the vehicle Attach the appropriate switch cover i e FRONT or REAR to the switch NOTE Refer to Figure 24 for the correct switch terminal identificat...

Page 36: ...ration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on Attach the REAR AIR LOCKER switch cover to SWITCH 1 and the FRONT AIR LOCKER switch cover to SWITCH 2 NOTE Refer to Figure 24 for the correct switch terminal identification and switch orientation Configure SOLENOID 1 as the air line leading to the rear axle Air Locker and SOLENOID 2 as the air line leading to the front axle A...

Page 37: ...r a period of at least 15min Air system recharging within that time period would indicate that a leak is present in the system NOTE If an alternate air source e g an air cylinder or a belt driven air pump is used instead of a compressor the air system will have to be leak tested with a pressure gauge and a shut off valve in series before the solenoid input If a leak is found to be present spray a ...

Page 38: ...e turning in the opposite direction without any resistance or mechanical noise from within the differential Turn the Air Locker switch to the ON position The illuminated symbol on the switch cover should light up Rotate the same wheel again Both wheels should rotate together Turn the switch off again Rotate the same wheel The wheels should again rotate in opposite directions 7 3 Filling the Differ...

Page 39: ...been filled to the correct level All air lines and wiring have been securely cable tied to resist snagging Switch es have been securely mounted within operator reach yet well away from danger of accidental engagement Switch es function properly and illuminate to indicate that Air Locker s are engaged All operators who are to use the Air Locker have read and fully understand the ARB Air Locker Oper...

Page 40: ...7 Testing Final Assembly 38 ...

Page 41: ...8 Parts List 39 8 1 Exploded Assembly Diagram See itemized parts list overleaf Figure 27 ...

Page 42: ...S 160206 14 8 RETURN SPRINGS 150113 15 1 SPLINED SIDE GEAR 728J071 16 4 PINION GEAR 728J071 17 4 PINION THRUST WASHER 151112 18 1 SPIDER BLOCK 070503 19 1 DIFFERENTIAL CASE 013110 1 BULKHEAD FITTING KIT O RING TYPE 170111 1 PUSH IN FITTING 5mm to 1 8 BSPP 170201 1 NIPPLE 1 8 to 1 8 BSPT 170501 1 AIR LINE 5mm DIA X 6m LONG 170301 1 SOLENOID VALVE 12V 180103 1 ON OFF SWITCH 180209 1 SWITCH COVER FRO...