Airlocker RD110 Manual de usuario
RD110
MITSUBISHI IFS, 28 SPLINE
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 4x4 ACCESSORIES
Corporate Head Office
42-44 Garden St Tel: +61 (3) 9761 6622
Kilsyth, Victoria Fax: +61 (3) 9761 6807
AUSTRALIA
3137
Australian enquiries [email protected]
North & South American enquiries [email protected]
Other international enquiries [email protected]
www.arb.com.au
Table of Contents:
1
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
Removing the Differential Assembly
5
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
9
3.1
Approximate Backlash Shimming
9
3.2
Calculation & Selection of Backlash Shims
11
3.3
Mounting the Ring Gear
12
3.4
Installing the Carrier Bearings
13
3.5
Preload Shim Measurement
14
3.6
Drilling & Tapping the Bulkhead Port
16
3.7
Installing the Bulkhead Fitting
17
3.8
Installing the Seal Housing
17
3.9
Installing the Differential Center
18
3.10
Setting Up the Bulkhead Fitting
20
3.11
Final Assembly
21
3.12
Checking the Backlash
23
3.13
Bench Testing the Air Locker
24
3.14
Reinstalling the Differential Assembly
25
4 Installing the Air System
27
4.1
Mounting the Solenoid
27
4.2
Running & Securing the Air Line
29
4.3
Connection to the Bulkhead Fitting
30
5 Mounting & Connecting the Electrical System
32
5.1
Mounting the Actuator Switch(es)
32
5.2
Wiring the Actuator System
33
6 Testing & Final Assembly
36
6.1
Leak Testing
36
6.2
Testing the Air Locker Actuation
36
6.3
Re-Sealing & Filling the Differential
37
6.4
Note For ADD Equipped Vehicles
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
2
1 Introduction
3
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!
1 Introduction
4
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, Allan keys, and drills.
A dial indicator or other suitable measuring tool for checking ring &
pinion backlash.
A razor knife for nylon tubing.
A differential housing spreader to facilitate removal and installation
of the carrier.
A torque wrench (See vehicle service manual for required torque
range)
A lubricant drain reservoir.
A slide hammer for removing CV axles.
Suitable measuring tools to measure a differential for preload
shimming. (e.g., an automotive feeler gauge)
A 11.2mm [7/16”] drill and ¼”NPT tap for bulkhead fitting
installation.
An automotive bearing puller (2 jawed) 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)
A gasket sealant or replacement gasket for your differential.
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.
A selection of differential bearing shims to set-up preload and
backlash.
2 Removing the Existing Differential
5
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 in the air, chock the wheels (if necessary) and
leave the vehicle in neutral.
2.2 Differential Fluid Drain
Clean around the differential drain plug to prevent dirt from entering
the differential.
Position a fluid drain reservoir under the differential.
Remove the drain plug and drain all of the oil from the housing.
HINT : This is a good time to check for metal particles in
your oil and on the end of the magnetic drain plug,
which may indicate a worn bearing or differential
component.
Once drained, reinstall the drain plug.
2.3 Removing the Differential Assembly
Remove the stub axles from the differential housing according to
your vehicle manufacturer’s service manual.
NOTE : Rubber oil seals can be easily damaged. Support the
weight of the axle when extracting it across the edges
of the seals.
Disconnect the drive shaft from the pinion flange.
Completely remove the entire differential assembly.
2 Removing the Existing Differential
6
2.4 Marking the Bearing Caps
Secure the differential assembly to a workbench.
Completely remove the front access cover.
Using a small pointed center punch, gently 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.
Figure 1.
HINT : Many installers choose to make one punch mark on
the left hand side of the left hand bearing cap and a
similar 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.
2 Removing the Existing Differential
7
2.5 Checking the Current Backlash Amount
IMPORTANT:
This step is a precautionary measure recommended by ARB due
to the fact that some aftermarket 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.
2 Removing the Existing Differential
8
2.6 Removing the Differential Center
Remove the floating shaft or ADD (Automatic Differential
Disconnect) unit (if present) from the side of the differential
housing.
Remove the bearing cap retaining bolts and then remove both
bearing caps.
Gently pry the differential center forward until it comes free of the
housing.
NOTE : Be sure not to mix up the left and right hand tapered
roller bearing cups or preload shims. Later it will be
necessary to know which cup came from which
bearing and which shim came from which side of the
differential.
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