The installation of an ARB Air Locker is a critical modification for off-road vehicles, offering enhanced traction control and durability under demanding conditions. Based on a detailed review of user experiences, technical instructions, and manufacturer guidelines, this article provides a structured overview of the ARB Air Locker installation process. The guide covers essential components, installation steps, sealing and leak prevention, electrical and compressor integration, and post-installation testing. Each section is informed by documented practices and warnings from experienced installers and official documentation.
Essential Components and Tools
The ARB Air Locker installation requires a comprehensive set of components, each with a specific role in ensuring the system operates effectively. According to the source materials, the standard ARB locker kit includes the following:
- Locking Carrier: The core mechanism that engages and disengages the locker.
- Air Solenoid and Switch: Controls the activation of the locker using an air pressure system.
- Air Fittings and Hoses: Connect the solenoid to the air compressor and differential housing.
- Special Bearings and Shims: Ensure proper clearance and alignment during assembly.
- Thread Sealant and Teflon Tape: Critical for preventing air and fluid leaks.
In addition to the ARB locker kit, the installation also requires a set of tools and materials, including a hydraulic press for bearing installation, a torque wrench, cutting and measuring tools for air line routing, and diff oil for lubrication. The use of a diff spreader is recommended for precise bearing alignment, though alternative methods, such as using a brass punch and hammer, have been reported in practical installations.
Preparation and Differential Cleaning
Before installing the ARB Air Locker, it is essential to prepare the differential housing by removing all existing components and cleaning the area thoroughly. This step is crucial to prevent contamination of the new bearings and gears. As outlined in the source documentation, the process involves:
- Removing the Stock Housing: This is often necessary if the original housing is damaged or bent, as was the case in one documented installation.
- Cleaning the Differential Area: Any dirt, grime, or old lubricant must be removed to ensure a clean surface for new components.
- Painting and Sealing: After cleaning, the axle and differential housing are often painted to prevent corrosion and improve aesthetics.
This preparatory work not only facilitates the installation but also ensures long-term reliability and performance of the system.
Installing the ARB Locker Carrier and Bearings
The core of the ARB installation lies in the correct placement and assembly of the locker carrier and bearings. The process involves several precise steps to ensure the locker functions as intended:
- Pressing in the Bearings: The outer and inner bearings are installed using a hydraulic press and a piece of tubing to avoid damaging the bearing surfaces.
- Applying Sealant: Thread sealant or Teflon tape is used on all threaded connections to prevent air and oil leaks.
- Mounting the Ring Gear: The ring gear is carefully aligned with the carrier using a technique that involves heating the ring gear to expand it slightly, making it easier to fit onto the carrier. Once in place, it is secured with bolts and thread-locking compound.
- Adjusting Clearance: Shims are used to maintain proper gear clearance and backlash. This is verified using a dial indicator and adjusted as necessary to meet specifications.
It is important to note that the absence of the original gear set can complicate the installation process, as seen in one documented case where the installer had to rely on a professional for gear setup.
Air Line Routing and Bulkhead Fitting
Proper routing of the air lines and installation of the bulkhead fitting are essential for maintaining air pressure and preventing leaks. The process includes the following steps:
- Bending the Air Line: The airline is bent to fit the differential housing while ensuring it does not interfere with other components.
- Installing the Bulkhead Fitting: A spring-loaded fitting is used to secure the air line to the differential housing, preventing it from being crimped during articulation.
- Securing the Air Line: Once the bulkhead is in place, the airline is connected to the solenoid and sealed with thread sealant.
In cases where a diff spreader is not available, alternative methods such as using a brass punch and hammer may be employed to install the locker into the housing. It is important to avoid using a sledgehammer or other heavy tools, as they can damage the locker.
Compressor Installation and Electrical Integration
The ARB Air Compressor is a key component that powers the locker system. The installation process for the compressor includes:
- Mounting the Compressor: The compressor is typically mounted near the battery and connected directly to it for power. A wiring harness is provided that includes a switch, relay, and pressure switch.
- Wiring the System: The harness is connected to a keyed ignition source and includes provisions for the locker switch. The system is designed so the locker cannot be activated unless the compressor is running. Additionally, in setups with both front and rear lockers, the front locker can only be engaged after the rear locker is activated.
- Pressure Switch Installation: This component is critical for recharging the system after use. It is connected to the compressor and ensures the air pressure is maintained at the required level.
The use of a manifold or remote coupling setup is recommended for systems that include tire inflation capabilities. For manifold installations, thread sealant is applied to all fittings and the hose is routed to a suitable location. For remote couplings, specific adapters and fittings are used to prevent kinks and ensure a secure connection.
Leak Testing and Final Checks
Once the installation is complete, it is essential to test the system for leaks and verify that the locker functions correctly. The following steps are recommended:
- Applying Teflon Paste: Where required, Teflon paste is applied to ensure airtight seals.
- Connecting the Air Line: The blue air hose is connected to the push-in fitting and checked to ensure it is seated properly.
- Reconnecting the Battery and Testing: The battery is reconnected, and the compressor switch is turned on briefly. The system should activate without cycling repeatedly, which would indicate a leak.
- Leak Detection: A soapy water solution is sprayed on all connections to check for bubbles, which indicate leaks. If leaks are found, the Teflon tape or sealant should be reapplied.
After the system has been confirmed to be leak-free, the locker should be tested by engaging it and observing the behavior of the front hubs. When engaged, both wheels should turn in the same direction. If this is not the case, further adjustments or troubleshooting may be necessary.
Real-World Testing and Performance
In real-world testing, as reported in the source materials, the ARB Air Locker significantly improves off-road performance. One user noted that the locker allowed for tighter turns and more controlled movement over rough terrain. However, it was also observed that the reduced turning radius when the locker is engaged can affect maneuverability in certain situations. This highlights the importance of knowing when to engage and disengage the locker based on driving conditions.
Conclusion
The installation of an ARB Air Locker is a complex but rewarding modification that enhances the performance of off-road vehicles. The process requires careful preparation, precise assembly, and thorough testing to ensure the system functions reliably. Key considerations include the use of high-quality tools and materials, proper sealing of all connections, and adherence to manufacturer guidelines. When installed correctly, the ARB Air Locker provides improved traction, durability, and control in challenging off-road environments.