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
2.128

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
RD128

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
GM 8.5/10 Bolt/AAM 860, 30 SPL
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
Land Rover,24 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
24

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
3.54

ARB AIR LOCKER Air Operated Locking Differentials

TABLE OF CONTENTS
2 Air Locker Differential Parts Lists
Section

Part No.

Description

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
2.152
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
2.188
2.189
2.193

RD129
RD131
RD132
RD133
RD134
RD135
RD136
RD137
RD138
RD139
RD140
RD141
RD142
RD143
RD144
RD145
RD146
RD147
RD148
RD149
RD150
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
RD188
RD189
RD193

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
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 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
Dana 60XHD,40 SPL,4.56 & UP
Dana 60XHD,40 SPL,4.10 & DN
Toyota 8 RR,12 Bolt RG,Shim adjusted

NOTE:

Contact ARB directly for model numbers not listed here.

3 of 5

Splines

Ratio

30
30
30
30
31
33
31
33
24
30
35
34
30
32
34
16
36
35
28
32
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
40
40
30

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
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
4.56 & UP
4.10 & DN
All

ARB AIR LOCKER Air Operated Locking Differentials

TABLE OF CONTENTS
2 Air Locker Differential Parts Lists
Section

Part No.

Description

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

RD195
RD196
RD197
RD198
RD200
RD201
RD202
RD203
RD204
RD205
RD206
RD207
RD208
RD209
RD210
RD212
RD213
RD214
RD215
RD216

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

NOTE:

Contact ARB directly for model numbers not listed here.

Splines

Ratio

34
31
33
30
16
31
29
17
26
22
22
22
26
26
28
28
26
34
37
30

All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
3.73 & UP

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 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

4 of 5

ARB AIR LOCKER Air Operated Locking Differentials

TABLE OF CONTENTS
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