RD165 ARB 4×4 RD165 Air Locker Differential Owner’s Manual

: June 1, 2024
: ARB

Table of Contents

RD165 ARB 4×4 RD165 Air Locker Differential
Specifications:
Product Usage Instructions:
1. Pre-Installation Preparation
2. Removing the Existing Differential
3. Installing the Air Locker
4. Installing the Air System
5. Mounting & Connecting the Electrical System
6. Testing & Final Assembly
- FAQ:
Q: Can I install the Air Locker myself?
Q: What should I do if I encounter difficulties during

RD165 ARB 4×4 RD165 Air Locker Differential

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Specifications:

Model: RD165
Axle Type: DANA 60
Spline Count: 32
Gear Ratio: 4.10 & Down
Operation: Air Operated Locking Differential

Product Usage Instructions:

1. Pre-Installation Preparation

Before starting the installation process, it is highly
recommended to read through the entire installation guide and your
vehicle manufacturer’s service manual thoroughly.

2. Removing the Existing Differential

Follow the steps outlined in the manual for safely removing the
existing differential from your vehicle. This includes proper
vehicle support, differential fluid drainage, and disconnecting the
axles.

3. Installing the Air Locker

Ensure proper oil drainage, shim the backlash, mount the ring
gear, and follow the detailed steps for drilling, tapping, and
assembling the air locker components.

4. Installing the Air System

Mount the solenoid, run and secure the air line, and connect it
to the bulkhead fitting according to the provided instructions.

5. Mounting & Connecting the Electrical System

Mount the actuator switch(es) and wire the actuator system as
per the guidelines provided in the manual.

6. Testing & Final Assembly

Perform leak testing, reinstall the axles, test the air locker
actuation, reseal, and fill the differential. Complete a
post-installation checklist to ensure everything is in order.

FAQ:

Q: Can I install the Air Locker myself?

A: While the installation guide provides detailed instructions,
it is recommended to have your Air Locker installed by a trained
professional for optimal results.

Q: What should I do if I encounter difficulties during

installation?

A: If you face challenges during installation, it is best to
contact ARB or an authorized distributor for assistance and
guidance.

“`

RD165
DANA 60, 32 SPLINE, 4.10 & DOWN
AIR OPERATED LOCKING DIFFERENTIAL
INSTALLATION GUIDE

No liability is assumed for damages resulting in the use of the information contained herein.
ARB Air Locker Air Operated Locking Differentials and Air Locker are trademarks of ARB Corporation Limited. Other product names used herein are for identification purposes only and may be trademarks of their respective owners.

ARB 4×4 ACCESSORIES

Corporate Head Office

42-44 Garden St Kilsyth, Victoria AUSTRALIA 3137

Tel: +61 (3) 9761 6622 Fax: +61 (3) 9761 6807

Australian enquiries North and South American enquiries Other international enquiries

sales@arb.com.au sales@arbusa.com exports@arb.com.au

www.arb.com.au

Table of Contents:

1 Introduction

3

1.1 Pre-Installation Preparation

3

1.2 Tool-Kit Recommendations

4

2 Removing the Existing Differential

5

2.1 Vehicle Support

5

2.2 Differential Fluid Drain

5

2.3 Disconnecting the Axles

6

2.4 Marking the Bearing Caps

6

2.5 Checking the Current Backlash Amount

7

2.6 Removing the Differential Center

8

3 Installing the Air Locker

10

3.1 Insuring Adequate Oil Drainage

10

3.2 Approximate Backlash Shimming

11

3.3 Mounting the Ring Gear

15

3.4 Drilling and Tapping the Bulkhead Port

16

3.5 Assembling the Seal Housing

17

3.6 Pre-Load Shimming

18

3.7 Reinstalling the Bearing Caps

20

3.8 Checking the Backlash

21

3.9 Setting Up the Bulkhead Fitting

22

3.10 Profiling the Seal Housing Tube

24

3.111 Bench Testing the Air Locker

25

4 Installing the Air System

26

4.1 Mounting the Solenoid

26

4.2 Running & Securing the Air Line

28

4.3 Connection to the Bulkhead Fitting

29

5 Mounting & Connecting the Electrical System

31

5.1 Mounting the Actuator Switch(es)

31

5.2 Wiring the Actuator System

32

6 Testing & Final Assembly

36

6.1 Leak Testing

36

6.2 Reinstalling the Axles

36

6.3 Testing the Air Locker Actuation

37

6.4 Re-Sealing & Filling the Differential

37

6.5 Post-Installation Check List

38

7 Parts List

39

7.1 Exploded Assembly Diagram

39

7.2 Specifications

39

7.3 Itemized Parts List

40

1

2

1 Introduction
IMPORTANT :
BEFORE ATTEMPTING TO DISMANTLE YOUR VEHICLE FOR THIS INSTALLATION, PLEASE READ THIS INSTALLATION GUIDE IN ITS ENTIRETY, AS WELL AS ALL APPLICABLE SECTIONS OF YOUR
VEHICLE MANUFACTURER’S SERVICE MANUAL.

1.1 Pre-Installation Preparation

This booklet is to be used in conjunction with your vehicle manufacturer’s service manual. ARB endeavors to account for every possible variation in vehicle model when publishing its installation guides, and guides are updated regularly as new model information becomes available, however, the rapid and globally varied release of some vehicles makes it difficult to insure that your vehicle model has been accurately accounted for. In the case of any technical discrepancies between this guide and your service manual, we strongly advise that you adhere to the specifications and techniques as documented in your service manual.

Although 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 experience and skill from years of performing similar installations.
Once you begin this installation your vehicle will be immobile until all steps of the installation are complete. Make sure your Air Locker kit is the correct model for your vehicle and that it contains all of the parts listed on back cover of this booklet. Also be sure you have appropriately equipped yourself with all the necessary tools, parts, and materials to complete this installation (see section 1.2 Tool-Kit Recommendations), and that you have allowed for an appropriate amount of vehicle down time.

HINT :

Place a mark inside each of the symbols as
you complete each step. It is very important NOT to miss any of the steps!

3

1 Introduction
1.2 Tool-Kit Recommendations
Below is a list of tools and supplies you may need to complete this installation. Requirements for your vehicle may vary. Please consult your vehicle service manual for additional recommendations.
1.2.1 Tools
Standard automotive sizes (metric and/or imperial) of sockets, wrenches, Alan keys, and drills.
A dial indicator or other suitable measuring tool for checking ring & pinion backlash.
A standard automotive feeler gauge. A razor knife to cut the nylon tubing. A differential housing spreader, to facilitate removal of the carrier.
(e.g., ARB Differential Spreader #0770003) A torque 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 3.2) A 11.2mm [7/16″] drill and ¼” 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 arbor press.
1.2.2 Supplies
Thread lubricant/sealant compound for pressure fittings (e.g., LOCTITE #567 Teflon paste)
Thread locking compound (e.g., LOCTITE #272) Either a replacement gasket, or gasket sealant, for your differential
cover. A sufficient volume of differential oil to completely refill your
housing. (see the ARB Air Locker Operating and Service Manual for recommended lubricants) A soap and water mixture to test for air leaks.
4

2 Removing the Existing Differential

2.1 Vehicle Support
Safely secure the vehicle on a hoist. We recommend supporting the vehicle on a chassis hoist to keep the differential area at a convenient working height and to leave the wheels and axles free to be rotated and removed.
Once supported off the ground, release the parking brake and leave the vehicle in neutral. Chock the wheels if necessary.

2.2 Differential Fluid Drain

HINT :

This is a good time to check for metal particles in your oil, on your drain plug, or in the bottom of the housing which may indicate a worn bearing or differential component.

Clean around the differential cover plate seal to prevent dirt from entering the differential.
Position a fluid drain reservoir under the differential and loosen all differential cover plate retaining bolts.
If a drain plug exists, remove it and completely drain all differential oil from the housing.
If no drain plug exists then the oil can be drained by loosening the cover bolts and gently prying the cover away at the bottom until oil runs out.

HINT :

If a drain plug does not exist then it would be a good idea to drill and tap for a tapered oil drain plug to assist with future oil changes.

Once drained, remove the differential cover plate.

5

2 Removing the Existing Differential

2.3 Disconnecting the Axles

IMPORTANT :
Collision damage or heavy off-road use of your vehicle in the past may have resulted in some degree of bending in the axle. Any misalignment
of the axle tubes may result in excessive wear and/or failure of your differential and axle shafts. ARB strongly recommends that you have your axle assembly inspected for concentricity and straightness before
installing your Air Locker.

Remove the wheels, and brakes according to your vehicle manufacturer’s service manual.
Remove both axle shafts according to your vehicle manufacturer’s service manual.

NOTE :

The axle oil seals are delicate and can be easily
damaged. Support the weight of the axle shaft when drawing them out of their sockets in the housing.

2.4 Marking the Bearing Caps

Using a pointed center punch, gently mark the bearing caps in a way that will enable you to know which cap is LEFT’ and which cap isRIGHT’, which way is UP’ and which way isDOWN’. (Fig.1.)

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 designated with two punch marks on the right hand side of the cap
and two similar punch marks on the housing.

Figure 1.

6

2 Removing the Existing Differential
2.5 Checking the Current Backlash Amount
IMPORTANT:
This step is a precautionary measure recommended by ARB due to the fact that some after market ring and pinion sets have been manufactured to run with different backlash settings than those
specified by your vehicle manufacturer. Although ARB must recommend you set backlash according to your service manual
guidelines, we also advise that you compare the backlash measurements taken here to the recommended backlash settings
in your vehicle service 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.
Figure 2.
While supporting the pinion gear by holding the drive shaft flange, rotate the differential in both directions while observing the maximum variation in depth from the indicator (i.e., the highest value minus the lowest value). This value is referred to as the ring and pinion backlash.
Rotate the differential center 90 and measure again for accuracy. Record the average of all measurements.
7

2 Removing the Existing Differential

2.6 Removing the Differential Center

IMPORTANT:
YOU MUST SPREAD THE HOUSING
Spreading the differential housing with a differential case spreader is a step which is critical to set up bearing pre-load (See Figure 3.). Improper pre- load will result in undue bearing wear, increased stresses in the differential center, increased running noise, and ultimately, ring and pinion gear damage.

Remove both bearing caps.
Carefully spread the housing (Fig.3.) enough to remove the differential center. (Refer to your vehicle’s service manual).

NOTE : Do not spread the housing more than 0.50mm [0.020″].

HINT :

Be sure not to mix up the left and right hand bearing
cups. Later it will be necessary to know which cup came from which side.

Once the housing has been adequately spread, the differential may be removed by pulling forward on the differential carrier.

Figure 3.

8

2 Removing the Existing Differential
NOTE : The differential center is heavy and quite difficult to handle when covered in oil. Take care not to drop it.
Relieve any tension on the spreader immediately after the differential has been removed.
9

3 Installing the Air Locker
3.1 Insuring Adequate Oil Drainage IMPORTANT:
Some Salisbury axles were manufactured with poor oil drainage between the axle tubes and the differential housing. This can
often result in one of the axle tubes filling up with differential oil while running. In most cases this will result in a blocked air vent which will cause the differential housing to pressurize and expel
oil from the axle seals at the wheels or force oil into the air system of the Air Locker, eventually expelling oil at the solenoid
valve. This is a design flaw which was corrected by most automakers in the later releases of their axle assemblies. If no lower drainage point is present in the differential housing then it
is critical that you modify the housing to include one. Inspect the differential housing for the presence of adequate
drainage in both axle tubes (refer to Fig.4.).
Figure 4.
If no drainage slot is present at the left-hand side (refer to Fig.4.) of the housing at all, then a slot will have to be created as clearance for the seal housing tube (Refer to Section 3.8 Reinstalling the Bearing Caps).
If drainage exists but is inadequate then a slot or hole should be cut into the housing on the lower side of the tube(s) to allow oil out of the axle tube area.
10

3 Installing the Air Locker
NOTE : Make sure any grinding dust, filings or drill chips left behind by cutting the drainage slots is completely cleaned out of the housing.
Check that the axle air vents are clear and working correctly.
3.2 Approximate Backlash Shimming
In order to reproduce a similar pre-load and ring and pinion backlash in your Air Locker to that of your original differential, measurements need to be taken so that a shim thickness can be calculated. Secure the original differential to a work bench. 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.
Figure 5.
Assemble the original bearing cup onto the cone of the right-hand side of the original differential carrier.
11

3 Installing the Air Locker

Using a caliper or similarly accurate measurement method (i.e., able to take accurate measurements within 0.04mm [0.0015″]),
measure the distance from the shoulder of the outer face of the bearing cup to the ring gear mounting face (shown as A’ in Figure 5.) and record this measurement asA’.

NOTE : Be sure to measure using the bearing cup that originally came off of the right-hand side.

Remove the bearings from the original carrier using an automotive bearing puller (ARB #0770001). Inspect the bearings for wear or damage and replace if necessary.

Apply a thin film of high pressure grease to both bearing journals of the Air Locker to prevent seizing.
Using a bearing press or arbor press, press one of the bearing cones onto one bearing journal of the Air Locker (refer to Figure 6.) until the bearing seats firmly against the bearing journal shoulder.

NOTE :

Do not add any shims between the bearings and the
bearing seat, even if they were present on the OE carrier.

Figure 6.
Invert the Air Locker and press the other tapered roller bearing cone onto the opposite bearing journal of the differential carrier until the bearing seats firmly against the bearing journal shoulder.
12

3 Installing the Air Locker
Assemble the new bearing cup onto the right-hand side of the Air Locker (as shown in Fig. 7.) and measure the total distance C’. NOTE : The shim packB’ will be determined and added later.

Figure 7.
Record this measurement as C’. The thickness of the shim packB’ should make the distance C’ on the Air Locker closely match the distanceA’ on the existing differential (within 0.1mm [0.004″] ).
Use the following calculation to find the desired thickness of `B’:

A C = B (Replacement Shim Pack)

HINT :

If your calculations are correct then the following equation will also be true:
A B C = ZERO

13

3 Installing the Air Locker

Select shims from the shim kit supplied with your Air Locker to make the thickness `B’ as determined above.

NOTE :

If necessary, shim kit `B’ can be made from the standard Dana shims (not supplied) and put between the bearing cone and bearing seat.

Place this shim pack on the bearing cup.

Re-measure the new distance C’ from the Air Locker (now including the shim packB’) to make sure that it matches `A’ on the original differential.

NOTE : NEVER machine the Air Locker.

14

3 Installing the Air Locker

3.3 Mounting the Ring Gear

Apply a thin film of high pressure grease to the ring gear shoulder of the Air Locker to prevent seizing.
Thoroughly clean any thread locking compound or other foreign matter from the holes of the ring gear, the threads of the ring gear bolts, and the mating surfaces between the ring gear and the Air Locker flange.

HINT : Stoning the ring gear mounting face before installation will remove any high spots around the threads.
Heat the ring gear to between 80 and 100C [175 – 212F] in hot water or in an oven to slightly expand the gear and facilitate assembly.

NOTE :

NEVER HEAT GEARS WITH A FLAME! This could
damage the hardened surface of the gear and result in premature wear or failure.

Dry the gear and bolt holes with compressed air (if wet).

Install the ring gear onto the Air Locker by aligning the bolt holes and then gently tapping it around in a circle with a soft mallet. Avoid using the bolts to pull down the ring gear as this puts excess strain on the bolts and the differential flange.

Apply a thread locking compound to the thread of each ring gear bolt before inserting it. Do not apply threading compound directly into the threaded hole as this could prevent the bolt from reaching its full depth.

Tighten the ring gear bolts in a star pattern with a torque wrench according to your vehicle manufacturer’s specified torque.

15

3 Installing the Air Locker

3.4 Drilling and Tapping the Bulkhead Port
An airline port must be drilled and tapped through the differential housing to mount the bulkhead fitting into.

NOTE :

Higher ratio gearing uses deeper (thicker) ring gears
with teeth that extend much further. Make sure the intended hole location is far enough away from the ring gear teeth that the air line will not be at risk of contact with the current or future ring gears.

Mark a position on the top of the outside shell of the differential housing in either of the positions shown in Figure 8. Choose the position that is more suited to giving maximum clearance around the bulkhead fitting. The bulkhead position must allow the seal housing tube (assembled at a later time) to be clear of the ring gear position.

Figure 8.

Cover the drive pinion and axle tube areas with a rag to protect them from metal filings.
Drill through the housing square to the outside surface using a 11.2mm [7/16″] drill.
Tap the hole from the outside using a ¼” NPT pipe tap. Remove any sharp edges from the hole that may chip-off and fall
into the housing. Carefully remove the rags and inspect with a service light inside the
housing to ensure no metal filings are left behind.
16

3 Installing the Air Locker 3.5 Assembling the Seal Housing

Figure 9.

Make sure the grooves and airway of the seal housing are clean and free from any contaminants (e.g. water, dirt, metal filings, etc.).
Inspect the seal housing O-rings (supplied) for dirt, damage or other conditions which might cause leaks.
Generously lubricate the O-rings with oil prior to assembly, then insert them into the grooves of the seal housing.

NOTE :

When assembling the O-rings, be careful not to leave
them twisted when seated in the grooves as this could cause excessive wear and leakage.

Lubricate the seal housing running surface on the Air Locker carrier with oil. Assemble a bearing cup onto the left-hand side of the Air Locker.

With the stepped side towards the bearing, carefully install the seal housing by sliding it all of the way onto the bearing journal with a gentle twisting motion. This will allow the O-rings to engage gently.

IMPORTANT :
A 4mm Master Shim is supplied for use with the “thin” bearing cup (382A). Do not use this shim with the “thick” bearing cup (382-S).

17

3 Installing the Air Locker
3.6 Pre-Load Shimming
In order to pre-load the tapered roller bearings in your Air Locker, measurements need to be taken so that a value can be calculated for the shim thickness D’ in Figure 9. Insert and hold the Air Locker into the differential housing. Insert the shim pack determined earlier asB’ between the bearing
cup (right-hand side) and the axle housing. Push (or lightly pry) the Air Locker hard across to the right-hand
side, and measure the maximum gap (also called the `end float’) between the outside of the seal housing and the inside face of the axle housing with an automotive feeler gauge. (Fig.10.)
Figure 10.

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 `D’ in Figure 9.

PRE-LOAD + END FLOAT = SHIM PACK

Create a shim pack `D’ from the shims supplied with your Air Locker.

NOTE :

A wide variety of shims has been included in the shim
kit for your convenience and to cover various Dana 60 applications, however it should not be necessary to use them all.

18

3 Installing the Air Locker

NOTE :

Do not add shims between the bearing cone and the
bearing seat of the seal housing side and NEVER machine the Air Locker.

Remove the Air Locker from the axle housing.
Install the shim pack `D’ between the bearing cup and the seal housing as shown in Figure 9.
Spread the differential housing again (Refer to Section 2.6).
Re-install the Air Locker into the axle housing.

NOTE : NOTE :

If the Air Locker is too tight to fully install then the spreader tension may need to be increased. Do not spread the housing more than 0.50mm [0.020″].
Use the ARB Shim Driver #0770004 to install the supplied Air Locker shims.

Rotate the seal housing until the tube is pointing straight out of the axle housing.
Release all spreader tension.
Check that some backlash can be felt between the ring and pinion gears. No backlash would be an early indication of incorrect shim thickness.

19

3 Installing the Air Locker 3.7 Reinstalling the Bearing Caps
Install the bearing caps oriented as they were marked before they were removed, and tighten the bearing cap bolts. It is not necessary to torque them down at this time.
Check that some clearance exists between the bearing cap and the seal housing tube. If not, the bearing cap should be removed and the tube re-bent for adequate clearance.
Tighten all bearing cap bolts with a torque wrench to the torque specified in your vehicle manufacturer’s service manual.
20

3 Installing the Air Locker 3.8 Checking the Backlash
Set a depth indicator on one of the ring gear teeth as in Figure 11.
While supporting the pinion gear by holding the drive shaft, rotate the differential in both directions while observing the maximum variation in depth from the indicator (i.e., the highest value minus the lowest value). This value is referred to as the ring and pinion backlash.
Rotate the differential center 90 and measure again for accuracy.
Figure 11.
Refer 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 reshimmed.
3.8.1 Re-Shimming the Backlash
NOTE : This step is only necessary when adjusting for incorrect backlash.
Remove the bearing caps. Remove the differential as before. To decrease the amount of backlash, reduce the shim thickness B’ (Fig.7.) and increase the shim thicknessD’ (Fig.9.) by the same amount. Reverse this step to increase the backlash.
21

3 Installing the Air Locker
Remount the differential as before. Release spreader tension (if applicable). Check backlash again as before.
3.9 Setting Up the Bulkhead Fitting
Apply thread sealant to the outside threads of the bulkhead body. Screw the bulkhead body into the tapped hole, and lightly tighten
using a 14mm [9/16″] spanner. Wipe the area clean of any excess thread sealant (inside and
outside of the housing). Bend the seal housing tube to the approximate shape (Fig. 12.),
and trim to length using an automotive tube cutter. 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 one of the small O-rings
over the top of the short length of seal housing tube protruding through the bulkhead fitting. Install the brass spacer. Install the second small O-ring after the spacer. While holding the seal housing tube into the bulkhead fitting, insert the chamfered end of the center compression nut over the extended tube as shown in the assembly diagram (Fig. 13.), and screw it into the bulkhead body, and tighten using Pozidriv #3 screwdriver.
Figure 12.
22

3 Installing the Air Locker

Figure 13.

NOTE :

Make sure the seal housing tube is all of the way into
the center compression nut while you are tightening it.

NOTE : Firmly tighten the center compression nut so that a good seal is formed around the tube.

23

3 Installing the Air Locker
3.10 Profiling the Seal Housing Tube
Completely remove the differential spreader. Without using sharp, jagged tools such as pliers (usually your
hands are the best tool for this job), gently bend the seal housing tube so that it runs along the inside of the differential housing as shown in Figure 14.
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 tube and eventually cause a leak.

24

3 Installing the Air Locker

3.11 Bench Testing 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). Once 620 KPA [90 PSI] is reached close the valve, disconnect the air hose, and watch to see if there is any drop in pressure. If so, this will indicate an air leak. (Fig.15.)

Figure 15.

If a leak is found to be present, spray a soap and water mixture onto the bulkhead air fitting. Bubbles should appear at any leak points.
NOTE : Do not spray this soapy mixture inside the differential. Check that leaky fittings have been adequately tightened. Disassemble, clean threads, and reapply thread sealant if leaking
persists. If a leak is found at the seal housing, carefully remove the seal housing assembly and examine the O-rings. Be very careful with the O-rings and check for defects, damage, wear, or presence of foreign material in the O-ring grooves. Replace if necessary.
25

4 Installing the Air System

4.1 Mounting the Solenoid

4.1.1 Connection to an ARB Air Compressor (Fig.16.)

Remove one of the 1/8″ BSP plugs from its port in the compressor tank.
Apply Teflon paste to the 1/8″ BSP nipple on the solenoid and insert it into the port and tighten. The solenoid should be rotated into a position which does not obstruct any other ports on the compressor tank.

NOTE : NOTE :

The coil and stem of the solenoid can be removed to make installation easier.
The solenoid is marked with two #1 ports. If space is tight, a second solenoid can be “daisy-chained” off the first one by removing the plug from the redundant #1 port and screwing the nipple from the second solenoid into it (Fig. 16.).

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.

Assemble the 6mm push-in fitting into the solenoid outlet port (stamped “2”) and hand tighten.

Figure 16.

26

4 Installing the Air System

4.1.2 Connection to an Alternate Air Source

For ease of installation, quality of air supply, and a high level of dependability from your Air Locker(s), ARB strongly recommends use of a genuine ARB Air Compressor, however, the Air Locker air system can be operated on any alternate air source that meets each of the following guidelines:
Must supply a minimum of 85PSI [586kPa]. The Air source should have a tank capacity that enables it to
actuate the Air Locker(s) in one charge so that no hesitation is experienced when locking one or two differentials.

HINT :

A good way to insure that you have the necessary
capacity is to make sure you can engage, disengage, and then reengage 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 and secure it from the effects of vibration and shock.
Connect the air supply to the 1/8″ BSP inlet port of the solenoid (stamped “1” on the solenoid body) using thread sealant.

IMPORTANT :
ARB cannot warrant your Air Locker(s) against damage caused as a result of using an alternate air supply. If you have any doubts as to the suitability of your air system to use in an Air Locker system, consult your ARB distributor.

27

4 Installing the Air System

4.2 Running and Securing the Air Line

The path taken by the air line from your air source (i.e., compressor) to your Air Locker is unique to your vehicle and the position of your air source. Plan ahead carefully when running the air line and always follow these guidelines:

Account for axle travel when running the line from the axle to a fixed point on the vehicle. Leave enough slack in the air line to allow for maximum suspension travel in both directions. (Not necessary on IFS installations)
Avoid leaving large lengths of air line hanging underneath the vehicle where they may get tangled on rocks, sticks, etc.

HINT :

Cable tying the air line to one of your flexible brake
lines will account for axle travel and should help keep your line from getting snagged.

Run the air line all the way from the compressor to the differential before trimming either end of the line to length. This will save complications that may arise if the air line has to be removed.
Make sure the line does not contact sharp edges or abrasive surfaces that may damage the air line over time.
Do not run the air line around tight bends which 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 unusually large diameter hose, etc., will increase drain on the compressor tank resulting in the compressor running more often than needed.
Support the air line by tying it back with cable ties wherever possible.
At the solenoid end of the air line, always trim the line to length with a sharp knife to avoid distorting the tube where it plugs into the push-in fitting.

NOTE :

To remove the air line from the push-in fitting; push
the air line into the fitting as far as possible, then press the flange inward, then pull the air line free of the fitting.

28

4 Installing the Air System
To attach the air line to the push-in fitting of the solenoid; insert the line firmly into the fitting, pull outward on the flange of the fitting while holding the line as far into the fitting as possible, and then gently pull outward on the air line to clamp the line in place.
4.3 Connection to the Bulkhead Fitting
In the case of an IFS axle assembly or in the case that the axle assembly has been completely removed from the vehicle, the assembly will have to be remounted in order to position the bulkhead fitting in its correct location for air line access.
Trim the air line to length using a sharp knife. Assemble an aluminium washer onto the banjo bolt and insert
through the banjo fitting. Assemble second aluminium washer and tighten into bulkhead fitting using a 14mm [9/16″] spanner. (Fig.17.) Apply thread sealant to the tapered thread of the compression fitting body and screw into the banjo fitting. Tighten using a 12mm spanner. Insert the outer compression nut and ferrule over the air line. Ferrule should be orientated as per Fig.17.
Figure 17.
29

4 Installing the Air System

Push the airline into the compression fitting body and screw the outer nut down onto it. Using a 12mm spanner, tighten the outer nut onto the compression fitting body.

NOTE :

Some force is required to crush the ferrule, however the outer compression nut will tighten against a stop. Over tightening will not create a better seal.

Secure any loose sections of tube with a cable tie.

NOTE :

When right angle routing of the tube is not required, screw the compression fitting body straight into the bulkhead fitting body (Fig.17.).

30

5 Mounting & Connecting the Electrical System

5.1 Mounting the Actuator Switch(es)

Air Locker actuator switch(es) can be easily panel mounted inside the vehicle in a 21mm x 36.5mm [0.83″ x 1.44″] rectangular cutout.

NOTE :

Only attach the cover plate to the face of the switch
once the switch has been mounted and wired correctly as the cover plates are designed to be difficult to remove.

For reasons of safety and for ease of operation, the Air Locker actuator switch(es) should be mounted in a location picked to best suit the operator. Make sure you have taken the following points into consideration:

Switch(es) MUST be mounted and should never be allowed to simply dangle from the 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’ orOFF’) can be visually determined by the rocker position and the illumination state.
The position of the switch(es) should best eliminate any possibility of accidental operation by the driver or one of the passengers.
Switch cutout position(s) must be located in an area with a minimum of 50mm [2″] of clearance behind the face of the cutout.
Switch(es) should not be mounted where they will be exposed to water (e.g., in the lower section of an inner door panel).
ARB recommends that you apply the Air Locker Warning Sticker (ARB part # 210101) within close visual proximity of the switch location.

NOTE :

If no adequate position can be found on existing
dashboard panels, a surface mounted bracket (Fig. 18.) may be purchased from your ARB Air Locker distributor to suit 1, 2, or 3 switches.

31

5 Mounting & Connecting the Electrical System

Figure 18.

5.2 Wiring the Actuator System

5.2.1 Connection to an ARB AIR COMPRESSOR

When 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.19.)

NOTE :

180409 model loom shown for reference only. Refer to
your ARB Air Compressor Installation Guide for details on configuring your installation.

32

5 Mounting & Connecting the Electrical System
Figure 19.

SWITCH

TERMINAL

IDENTIFICATION

UP

Figure 20.

33

5 Mounting & Connecting the Electrical System 5.2.2 Connection to an Alternate Air Source
When connecting the actuation switch to an alternate air source, the switch(es) should be wired according to figures 21. and 22., depending on whether one or two Air Lockers will be installed in the vehicle.
5.2.2.1 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 21. 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’ orREAR’) to the switch.
NOTE : Refer to Figure 20. for the correct switch terminal identification and switch orientation.
SINGLE Air Locker SYSTEM
Figure 21.
34

5 Mounting & Connecting the Electrical System 5.2.2.2 Dual Air Locker System
If two Air Lockers are to be installed in the system, ARB recommends that the switches and solenoids be wired according to figure 22. For safety reasons, this configuration 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 20. 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 Air Locker.
DUAL Air Locker SYSTEM
Figure 22.
35

6 Testing & Final Assembly

6.1 Leak Testing

With the vehicle parked and the engine off, turn the compressor on and wait until the air system is fully charged.

NOTE :

With the Air Locker(s) disengaged, the air source (i.e.,
compressor) should not have to recharge over time. Intermittent recharging without Air Locker use usually indicates a leak at the solenoid fittings or at the compressor tank O-ring seal.

Actuate the Air Locker(s).

The compressor should not come on again for 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 soap and water mixture onto all air fittings in the system while the compressor is fully charged. Bubbles should appear at any leak points.

Check that leaky fittings have been adequately tightened.

Disassemble, clean threads, and reapply thread sealant if leaking persists.

6.2 Reinstalling the Axles
Insert both axles fully into the housing and gently tap them inward.
NOTE : Be careful not to damage the axle oil seals with the spline of the axle.
Reconnect the drive shaft to the differential drive flange. Reassemble the remainder of the differential assembly
(e.g., hubs, brakes, wheels, etc.) to the vehicle according to your vehicle’s service manual.

36

6 Testing & Final Assembly
6.3 Testing the Air Locker Actuation
To test that your air system, electrical system, and your Air Locker differential is functioning correctly: Support the vehicle such that the wheels are free to rotate (e.g., on
axle stands, a chassis hoist, etc.) Leave the parking brake off, the transmission in neutral, and the Air
Locker switch OFF’. Turn the ignition to theON’ position (leaving the motor off). The
large illuminating symbol on the Air Locker switch cover should be OFF’. Turn the compressor (or alternate air source) on to charge the air supply up to its maximum pressure. While supporting the drive shaft flange, rotate one wheel by hand. The wheel should rotate freely and the opposite wheel should be turning in the opposite direction without any resistance or mechanical noise from within the differential. Turn the Air Locker switch to theON’ 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.

6.4 Re-Sealing & Filling the Differential

NOTE :

Consult the ARB Air Locker Operating & Service
Manual for recommendations on differential lubricant specifications.

Replace the differential cover using gasket sealant or a new standard differential cover gasket for your make of vehicle.

Refill the differential until level with the filler hole.

Rotate the differential center 2 full turns.

Check the oil level and add oil if necessary.

Replace filler plug (apply thread sealant to filler plug before inserting if it is a threaded type plug).

Wipe differential housing clean of any oil or grease which may

collect dirt or other abrasive particles.

37

6 Testing & Final Assembly
6.5 Post-Installation Check List
Now that the Air Locker installation has been completed, ARB recommends that you take the time to complete the following check list just to insure that you haven’t missed any of the vital steps.
The air system has been leak tested.
Thread locking compound was used on the ring gear bolts.
All torque settings comply with the vehicle manufacturer’s specs and were set with an accurate torque wrench.
Differential fluid complies with ARB recommendations and has 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 Operating & Service Manual.
The Air Locker Warning Sticker has been located within close proximity of the actuator switch(es).

INSTALLATION PERFORMED BY: DATE OF INSTALLATION: ODOMETER READING:
ARB AIR LOCKER SERIAL No:

38

7 Parts List

RD165

Dana 60,32 SPL,4.10 & DN

7.1 Exploded Assembly Diagram

(See itemized parts list overleaf)

Figure 23.

7.2 Specifications

Axle Spline Ratio Supported
Ring Gear ID Ring Gear OD Ring Gear Bolts Ring Gear Torque
Backlash Bearing Cap Torque

32 tooth, Ø35.8mm [1.41″] 4.56:1 & up 162.0mm [6.38″] 248mm [9.75″] 12 bolts on Ø191mm [7.50″] 149Nm [110 ft-lb] 0.15-0.25mm [0.006-0.010″] 108Nm [80 ft- lb]

39

7 Parts List

7.3 Itemized Parts List
(See exploded diagram figure 23.)

ITEM #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 *

QTY
1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 2 4 4 2 1 1 1 1 1 1 1 1 1

DESCRIPTION
SEAL HOUSING O-RINGS (PK OF 2) SEAL HOUSING KIT SHIM KIT MASTER SHIM BONDED SEAL CLUTCH GEAR & WAVESPRING KIT CLUTCH GEAR & RETURN SPRINGS KIT SPIDER BLOCK LONG CROSS SHAFT SIDE GEAR COUNTERSUNK SCREW (PK OF 2) RETAINING PIN SET (PK OF 4) TAPERED ROLLER BEARING
FLANGE CAP KIT WAVESPRING RETURN SPRINGS KIT SPLINED SIDE GEAR SHORT CROSS SHAFT PINION GEAR PINION THRUST WASHER SIDE GEAR THRUST WASHER DIFFERENTIAL CASE (SUITS WAVESPRING ONLY) DIFFERENTIAL CASE (SUITS RETURN SPRINGS ONLY) BULKHEAD FITTING KIT (BANJO TYPE) AIR LINE (6mm DIA X 6m LONG) SOLENOID VALVE (12V) SWITCH|FR OR RR LOCKER CABLE TIE (PK OF 25) OPERATING & SERVICE MANUAL INSTALLATION GUIDE

PART #
160248-2 082104SP SHK001
SEE NOTE
160703SP 050907SP 050807SP 070402SP 061501SP
SEE NOTE
200214SP 120601SP
NOT SUPPLIED
028606SP 150707SP 150107SP
SEE NOTE
061601SP
SEE NOTE
SEE NOTE
SEE NOTE
013226SP 013206SP
170114 170314SP
180103 180225 180305 210200 2102165

NOTES 1
4
7 7
3
2
7 7 3
3 5 5 6 6 8 8

Not illustrated in exploded view

NOTES

1

For replacement O-rings use only BS140 Viton 75.

2

For replacement bearing use Timken part # 387A / 382S.

3

Available only as complete 6 gear set # 728K101.

4

Use 150331 (4.0mm thick) for diff with thin bearing cup.

5