SERVICE & PARTS MANUAL

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ARB Air Locker Air Operated Locking Differentials and Air Locker are trademarks of ARB Corporation Limited.

ARB AIR LOCKER Air Operated Locking Differentials TABLE OF CONTENTS 1 Introduction 1.1 1.2

Service & Parts Manual Introduction Air Locker Functional Description

2 Air Locker Differential Parts Lists Section

Part No.

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.12 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.30 2.31 2.32 2.33 2.35 2.36 2.37 2.38 2.39 2.40 2.41 2.42 2.43 2.44 2.45 2.46 2.47 2.50 2.51 2.53 2.54 2.55 2.56 2.57 2.60 2.64 2.65 2.66

RD01 RD02 RD03 RD04 RD05 RD06 RD07 RD08 RD09 RD10 RD12 RD16 RD17 RD18 RD19 RD20 RD21 RD22 RD23 RD24 RD25 RD26 RD27 RD28 RD30 RD31 RD32 RD33 RD35 RD36 RD37 RD38 RD39 RD40 RD41 RD42 RD43 RD44 RD45 RD46 RD47 RD50 RD51 RD53 RD54 RD55B RD56 RD57 RD60 RD64 RD65 RD66

Description

Toyota 8",45mm BRNG (replaced by RD132) Toyota 8.9",45mm BRNG (replaced by RD142) Land Rover,10 SPL,Banjo (replaced by RD127) Nissan H233,31 SPL (replaced by RD134) Mitsubishi 8”,RR,28 SPL (replaced by RD210) Dana 44,30 SPL,3.92 & UP (replaced by RD116) Dana 44,30 SPL,3.73 & DN (replaced by RD117) Toyota 8.9",C-clip,45mm BRNG (replaced by RD153) Nissan H233B,31 SPL (thrust block only - replaced by RD136) GM 10 Bolt,8.5",28 SPL (replaced by RD83) GM 12 Bolt,8.9”,30 SPL,3.73 & UP (replaced by RD216) Ford 8.8”,28 SPL (replaced by RD82) Nissan H233B,33 SPL (disc brake only - replaced by RD135) Dana 44,19 SPL,3.92 & UP (deleted from range) Dana 44,19 SPL,3.73 & DN (deleted from range) Land Rover,Salisbury,3.54:1 (replaced by RD161) Dana 60,30 SPL,4.56 & UP (replaced by RD162) Dana 60,30 SPL,4.10 & DN (replaced by RD163) Toyota 8",50mm BRNG (replaced by RD132) Nissan H233B,33 SPL (replaced by RD135) Mitsubishi 9”,RR,28 SPL (disc brake only - replaced by RD46) Land Rover HD,24 SPL (deleted from range) Nissan C200,29 SPL (replaced by RD202) GM 10 Bolt,8.5”,30 SPL (replaced by RD84) Dana 30,27 SPL,3.73 & UP (replaced by RD100) Dana 30,27 SPL,3.54 & DN (replaced by RD101) Land Rover,Salisbury,4.70:1 (replaced by RD160) Toyota 8.9",50mm BRNG (replaced by RD142) Dana 60HD,35 SPL,4.56 & UP (replaced by RD166) Dana 60HD,35 SPL,4.10 & DN (replaced by RD167) Ford 10.25” & 10.5” (Sterling / corporate) (replaced by RD140) Dana 35,non C-clip,27 SPL,3.31 & DN (replaced by RD103) Dana 35,non C-clip,27 SPL,3.54 & UP (replaced by RD102) GM 14 Bolt,9.5",C-clip (replaced by RD197) Mitsubishi Jeep,RR (deleted from range) Dana 60HD,C-clip,35 SPL,4.56 & UP (replaced by RD168) Dana 60HD,C-clip,35 SPL,4.10 & DN (replaced by RD169) Isuzu,RR,26 SPL (replaced by RD213) Mahindra,19 SPL (deleted from range) Mitsubishi 9”,RR,28 SPL (replaced by RD212) AMC Model 20,2.73:1 (replaced by RD187) Dana 50,30 SPL (replaced by RD158) GM / AAM 9.25",33 SPL (replaced by RD197) Dana 70HD,35 SPL,4.56 & UP (replaced by RD172) Dana 70HD,35 SPL,4.10 & DN (replaced by RD173) Ford 9",31 SPL (replaced by RD119) Land Rover,24 SPL,Banjo (replaced by RD128) Land Rover,24 SPL,Banjo,P38A (replaced by RD138) AMC Model 20,3.08 & UP (replaced by RD186) Toyota 9.5",32 SPL (replaced by RD152) Dana 70U,35 SPL,4.56 & UP (replaced by RD172) Dana 70U,35 SPL,4.10 & DN (replaced by RD173)

NOTE:

Contact ARB directly for model numbers not listed here.

1 of 5

Splines

Ratio

30 30 10 31 28 30 30 30 31 28 30 28 33 19 19 24 30 30 30 33 28 24 29 30 27 27 24 30 35 35 35 27 27 33 19 35 35 26 19 28 29 30 33 35 35 31 24 24 29 32 35 35

All All 3.54 All All 3.92 & UP 3.73 & DN All All 2.73 & UP 3.73 & UP All All 3.92 & UP 3.73 & DN 3.54 4.56 & UP 4.10 & DN All All All 3.54 All 2.73 & UP 3.73 & UP 3.54 & DN 4.7 All 4.56 & UP 4.10 & DN All 3.31 & DN 3.54 & UP All All 4.56 & UP 4.10 & DN All All All 2.73 All All 4.56 & UP 4.10 & DN All All All 3.08 & UP All 4.56 & UP 4.10 & DN

ARB AIR LOCKER Air Operated Locking Differentials TABLE OF CONTENTS 2 Air Locker Differential Parts Lists Section

Part No.

Description

2.68 2.69 2.70 2.71 2.72 2.73 2.74 2.75 2.77 2.78 2.79 2.80 2.81 2.82 2.83 2.84 2.85 2.87 2.88 2.89 2.90 2.91 2.92 2.93 2.94 2.95 2.96 2.97 2.98 2.99 2.100 2.101 2.102 2.103 2.104 2.105 2.106 2.107 2.109 2.110 2.111 2.112 2.113 2.114 2.115 2.116 2.117 2.118 2.119 2.121 2.123 2.124 2.125 2.126 2.127

RD68 RD69 RD70 RD71 RD72 RD73 RD74 RD75 RD77 RD78A RD79 RD80 RD81 RD82 RD83 RD84 RD85 RD87 RD88 RD89 RD90 RD91 RD92 RD93 RD94 RD95 RD96 RD97 RD98 RD99 RD100 RD101 RD102 RD103 RD104 RD105 RD106 RD107 RD109 RD110 RD111 RD112 RD113 RD114 RD115 RD116 RD117 RD118 RD119 RD121 RD123 RD124 RD125 RD126 RD127

Dana 35,C-clip,27 SPL,3.31 & DN (replaced by RD103) Dana 35,C-clip,27 SPL,3.54 & UP (replaced by RD102) Nissan H260,37 SPL (replaced by RD215) Nissan H260,37 SPL (disc brake only - replaced by RD215) Suzuki Sierra,RR,26 SPL (replaced by RD208) Suzuki Sierra,FR,22 SPL (replaced by RD205) Suzuki Vitara,RR,26 SPL,10 Bolt RG (replaced by RD204) Suzuki,FR,22 SPL,10 Bolt RG (replaced by RD205) Suzuki Jimny (JA),FR,22 SPL (replaced by RD207) Nissan H233B,31 SPL (replaced by RD136) Suzuki Vitara,RR,26 SPL,12 Bolt RG (replaced by RD209) Dana 80,35 SPL (replaced by RD173) Ford 8.8”,31 SPL Ford 8.8”,28 SPL GM 8.5”/10 Bolt/AAM 860, 28 SPL (replaced by RD221) GM 8.5”/10 Bolt/AAM 860, 30 SPL (replaced by RD222) Isuzu RR,23 SPL,non-LSD (deleted from range) Suzuki Jimny,FR,22 SPL,8 Bolt RG (replaced by RD207) Suzuki,26 SPL,10 Bolt RG (replaced by RD208) Toyota Tacoma,RR (replaced by RD129) Toyota 7.5” IFS Dana 80,37 SPL (replaced by RD175) Toyota 8" IFS,50mm BRNG (replaced by RD131) Chrysler 8.25",29 SPL Isuzu IFS,17 SPL (replaced by RD203) Dana 60,32 SPL,4.56 & UP (replaced by RD164) Dana 60,32 SPL,4.10 & DN (replaced by RD165) Dana 70,32 SPL,4.56 & UP (replaced by RD170) Dana 70,32 SPL,4.10 & DN (replaced by RD171) Ford 9",35 SPL,2” BRNG Dana 30,27 SPL,3.73 & UP Dana 30,27 SPL,3.54 & DN Dana 35,27 SPL,3.54 & UP Dana 35,27 SPL,3.31 & DN Dana 30,30 SPL,3.73 & UP Dana 35,30 SPL,3.54 & UP Nissan C200,31 SPL (replaced by RD201) Nissan C200/R200A,29 SPL (replaced by RD202) Dana 44,35 SPL,3.92 & UP Mitsubishi IFS,28 SPL Toyota 8” IFS,53mm BRNG,3.91 & UP Chrysler 8.25",27 SPL Dana 44,33 SPL,3.92 & UP GM 14 Bolt,10.5”,FF Dana 70HD,37 SPL,4.56 & UP (replaced by RD174) Dana 44,30 SPL,3.92 & UP Dana 44,30 SPL,3.73 & DN Suzuki Jimny,FR,22 SPL,10 Bolt RG (replaced by RD206) Ford 9”,31 SPL Toyota 8” IFS,53mm BRNG,3.73 & DN Mazda 8”,RR,shim adjusted Toyota 8.9”,C-clip,50mm BRNG (replaced by RD153) Dana 35,non C-clip,30 SPL,3.54 & UP Santana PS-10,RR Land Rover,10 SPL,Banjo

NOTE:

Contact ARB directly for model numbers not listed here.

2 of 5

Splines

Ratio

27 27 37 37 26 22 26 22 22 31 26 35 31 28 28 30 23 22 26 30 27 37 30 29 17 32 32 32 32 35 27 27 27 27 30 30 31 29 35 28 30 27 33 30 37 30 30 22 31 30 30 30 30 34 10

3.31 & DN 3.54 & UP All All All All All All All All All Varies by Mfg. All All 2.73 & UP 2.73 & UP All All All All All Varies by Mfg. All All All 4.56 & UP 4.10 & DN 4.56 & UP 4.10 & DN All 3.73 & UP 3.54 & DN 3.54 & UP 3.31 & DN 3.73 & UP 3.54 & UP All All 3.92 & UP All 3.91 & UP All 3.92 & UP 4.10 & DN 4.56 & UP 3.92 & UP 3.73 & DN All All 3.73 & DN All All 3.54 & UP All 3.54

ARB AIR LOCKER Air Operated Locking Differentials TABLE OF CONTENTS 2 Air Locker Differential Parts Lists Section

Part No.

Description

2.128 2.129 2.131 2.132 2.133 2.134 2.135 2.136 2.137 2.138 2.139 2.140 2.141 2.142 2.143 2.144 2.145 2.146 2.147 2.148 2.149 2.150 2.151 2.152 2.153 2.154 2.155 2.156 2.157 2.158 2.159 2.160 2.161 2.162 2.163 2.164 2.165 2.166 2.167 2.168 2.169 2.170 2.171 2.172 2.173 2.174 2.175 2.176 2.177 2.180 2.181 2.182 2.183 2.186 2.187

RD128 RD129 RD131 RD132 RD133 RD134 RD135 RD136 RD137 RD138 RD139 RD140 RD141 RD142 RD143 RD144 RD145 RD146 RD147 RD148 RD149 RD150 RD151 RD152 RD153 RD154 RD155 RD156 RD157 RD158 RD159 RD160 RD161 RD162 RD163 RD164 RD165 RD166 RD167 RD168 RD169 RD170 RD171 RD172 RD173 RD174 RD175 RD176 RD177 RD180 RD181 RD182 RD183 RD186 RD187

Land Rover,24 SPL,Banjo Toyota Tacoma,RR Toyota 8” IFS,50mm BRNG Toyota 8”,50mm BRNG Toyota 8” RR,shim adjusted Nissan H233,31 SPL Nissan H233B,33 SPL Nissan H233B,31 SPL Nissan R230,33 SPL,IRS,3.54 & UP Land Rover,24 SPL,Banjo,P38A AAM 11.5”,30 SPL Ford 10.25” & 10.5” (Sterling / corporate) Toyota 8” IFS,34 SPL,58mm BRNG (replaced by RD151) Toyota 8.9",50mm BRNG Dana 44,32 SPL,3.73 & DN Nissan H260,34 SPL (replaced by RD214) Rockwell 2.5T,16 SPL Toyota 10.5”,RR,36 SPL Dana 44,35 SPL,3.73 & DN AAM 760,28 SPL Nissan,M226,32 SPL,10 Bolt RG Ford 9.75”,34 SPL,C-Clip Toyota 8” IFS,34 SPL Toyota 9.5",32 SPL Toyota 8.9”,C-Clip,50mm BRNG Mitsubishi 9.5”,31 SPL,live axle Mitsubishi 9.5”,33 SPL,IRS Hyundai 9.5”,34 SPL,live axle Jeep JK Rubicon, 35 SPL Dana 50,30 SPL Nissan M226,32 SPL,12 Bolt RG Land Rover,Salisbury,24 SPL,4.70:1 Land Rover,Salisbury,24 SPL,3.54:1 Dana 60,30 SPL,4.56 & UP Dana 60,30 SPL,4.10 & DN Dana 60,32 SPL,4.56 & UP Dana 60,32 SPL,4.10 & DN Dana 60HD,35 SPL,4.56 & UP Dana 60HD,35 SPL,4.10 & DN Dana 60HD,C-Clip,35 SPL,4.56 & UP Dana 60HD,C-Clip,35 SPL,4.10 & DN Dana 70/80,32 SPL,LOW SPEED Dana 70/80,32 SPL,HIGH SPEED Dana 70/80,35 SPL,LOW SPEED Dana 70/80,35 SPL,HIGH SPEED Dana 70/80,37 SPL,LOW SPEED Dana 70/80,37 SPL,HIGH SPEED Dana 70/80,40 SPL,LOW SPEED Dana 70/80,40 SPL,HIGH SPEED Nissan R180A,27 SPL,3.69 & UP Nissan R180A,27 SPL,3.54 & DN Nissan R180A,27 SPL,8 Bolt RG Toyota 10.5”,RR,34 SPL AMC 20,3.08 & UP AMC 20,2.73 & DN

NOTE:

Contact ARB directly for model numbers not listed here.

3 of 5

Splines

Ratio

24 30 30 30 30 31 33 31 33 24 30 35 34 30 32 34 16 36 35 28 32 34 34 32 30 31 33 34 35 30 32 24 24 30 30 32 32 35 35 35 35 32 32 35 35 37 37 40 40 27 27 27 34 29 29

3.54 All All All All All All All 3.54 & UP All All All All All 3.73 & DN All All All 3.73 & DN All All All All All All All All All All All All 4.70 3.54 4.56 & UP 4.10 & DN 4.56 & UP 4.10 & DN 4.56 & UP 4.10 & DN 4.56 & UP 4.10 & DN xxx & UP xxx & DN xxx & UP xxx & DN xxx & UP xxx & DN xxx & UP xxx & DN 3.69 & UP 3.54 & DN All All 3.08 & UP 2.73 & DN

ARB AIR LOCKER Air Operated Locking Differentials TABLE OF CONTENTS 2 Air Locker Differential Parts Lists Section

Part No.

Description

2.188 2.189 2.193 2.195 2.196 2.197 2.198 2.200 2.201 2.202 2.203 2.204 2.205 2.206 2.207 2.208 2.209 2.210 2.212 2.213 2.214 2.215 2.216 2.217 2.218 2.219 2.220 2.221 2.222 2.223 2.224 2.226 2.227 2.228 2.229 2.230 2.231 2.232 2.234 2.235

RD188 RD189 RD193 RD195 RD196 RD197 RD198 RD200 RD201 RD202 RD203 RD204 RD205 RD206 RD207 RD208 RD209 RD210 RD212 RD213 RD214 RD215 RD216 RD217 RD218 RD219 RD220 RD221 RD222 RD223 RD224 RD226 RD227 RD228 RD229 RD230 RD231 RD232 RD234 RD235

Dana 60XHD,40 SPL,4.56 & UP Dana 60XHD,40 SPL,4.10 & DN Toyota 8” RR,12 Bolt RG,Shim adjusted Nissan Patrol Y62, RR Nissan C200K,31 SPL AAM 925/950,33 SPL VW Amarok Rear Rockwell 2.5T,40 SPL Nissan C200,31 SPL Nissan C200/R200A,29 SPL Isuzu IFS,17 SPL Suzuki Vitara,RR,26 SPL,10 Bolt RG Suzuki,FR,22 SPL,10 Bolt RG Suzuki Jimny,FR,22 SPL,10 Bolt RG Suzuki Jimny,FR,22 SPL,8 Bolt RG Suzuki,26 SPL,10 Bolt RG Suzuki Vitara,RR,26 SPL,12 Bolt RG Mitsubishi 8”,RR,28 SPL Mitsubishi 9”,RR,28 SPL Isuzu,RR,26 SPL Nissan H260,34 SPL Nissan H260,37 SPL GM 12 Bolt,8.9”,30 SPL,3.73 & UP LR Discovery 3 + 4, FR, 29 SPL LR Discovery 3, RR, 31 SPL T6 Ranger/BT50, FR, 29 SPL T6 Ranger/BT50, RR, 32 SPL GM8.5” 10 Bolt AAM 860, 28 SPL GM8.5” 10 Bolt AAM 860, 30 SPL Ford Ranger PJ, PK / Mazda BT50, IFS, 30 SPL Nissan M205, FR, 30 SPL Dana 44A, 30 SPL Suzuki Jimny,FR,26 SPL,8 Bolt RG Nissan C200K, FR, 34 SPL Nissan D23 RR, 34 SPL Nissan R180A,30 SPL,3.69 & UP Nissan R180A,30 SPL,3.54 & DN Toyota 8.9” RR, 12 Bolt RG, Shim Adjusted GM 14 Bolt,10.5”,40 SPL,FF GM 14 Bolt,10.5”,35 SPL,FF

NOTE:

Contact ARB directly for model numbers not listed here.

Splines

Ratio

40 40 30 34 31 33 30 16 31 29 17 26 22 22 22 26 26 28 28 26 34 37 30 29 31 29 32 28 30 30 30 30 26 34 34 30 30 32 40 35

4.56 & UP 4.10 & DN All All All All All All All All All All All All All All All All All All All All 3.73 & UP All All All All All All All All All All All All 3.69 & UP 3.54 & DN All 4.10 & DN 4.10 & DN

3 Compressor Parts Lists 3.1 3.2 3.3 3.4 3.5 3.6 3.7

On-Board Air Compressor Kit, Medium (RDCKA & RDCKA24) Portable Air Compressor (RDCP & RDCPA) On-Board Air Compressor Kit, Compact (CKSA12) On-Board Air Compressor Kit, High Output (CKMA12 & CKMA24) Portable Air Compressor Kit, High Output (CKMP12) On-Board Air Compressor Kit, Maximum Performance (CKMTA12 & CKMTA24) Portable Air Compressor Kit, Maximum Performance (CKMTP12)

4 of 5

ARB AIR LOCKER Air Operated Locking Differentials TABLE OF CONTENTS 4 Accessory Parts Lists 4.1 4.2 4.3 4.4 4.5

Bulkhead Fitting Kits Heavy Duty Air Line Kit (HDAL) Compressor Piston Service Kit Purge Valve Kit CKM Replacement Motor Cap

5 Tech Notes 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14

Screw Secured Seal Housing Set-up Spring Clip Secured Seal Housing Set-up Axle Identification Axle Modification Inspection for Bent Axles Ring and Pinion Gear Modifications Solenoid Valve Compressor Wiring Diagrams Compressor Fault Diagnosis Procedure Serial Number Interpretation Insuring Adequate Oil Drainage Installation in Ford Front Differentials Land Rover Salisbury Housing Modification Land Rover Axle Update

6 Appendix 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9

Service Guide Shim Kit Specifications Adjuster Nut Specifications Differential Ratio Calculator Differential Measurement Reference Packaging Weights and Dimensions Air Compressor Range Sizes & Specifications Tapered Roller Bearing Specifications Radial Seal Specifications (O-rings & X-rings)

5 of 5