This article only covers the installation of the carrier into the housing. The removal and installation of the housing is the same as a stock unit.

It is always a good idea to check the parts list included in the instruction booklet to be sure that nothing is missing. The photo above shows all the parts that are supplied to install the ARB carrier into a Samurai housing.

Tools

Preparation

The next step that we do at Petroworks results from many ARB installations in different types of differentials. It is very important that the part of the carrier that the "O" rings ride on is polished smooth so that the "O" rings will not wear out prematurely. If there is any roughness at all in this area, the life of the "O" rings may be very short, sometimes less than 500 miles. In the photo you can see the area that has been polished.

The next step is to remove the stock carrier from the housing and clean everything. Prior to removing the bearing caps, be sure to mark them so that they are installed on the correct side. Be sure that the bearings and races are also kept together.

It is not necessary to remove the pinion gear but be sure to check the pinion bearings. If there is any doubt as to the condition of the bearings or seal, this is the time to change them.

Assembly

Remove the carrier bearings and if they are in good condition press them onto the ARB carrier.

We use a hand arbor press (see picture at right) as it does not require much force to install the bearings. Be careful not to damage the polished area. Note which way the bearings go on, it"s irritating to have to pull the bearings off and turn them over.

Next drill a 7/16" diameter hole in the housing (pictured left). Be sure that the hole is not too close to the ring gear. If you have not removed the pinion, be sure to cover the bearings to keep the chips out while drilling and tapping.

The housing is cast iron so it is not recommended to use any type of oil for drilling and tapping.

Install the ring gear next using the original bolts and Locktite.

Torque the bolts to 65 ft. lb.

Install the carrier in the housing using the original adjuster on the ring gear side and the ARB adjuster on the other side.

Install the bearing caps and tighten the bolts to about 30 ft. lb.

Set the adjusters so there is a slight drag on the carrier bearings and .004 to .006 backlash. The backlash should be checked with a dial indicator as in this photo.

The slip ring is installed next. Do not put the "O" rings in yet! Place the slip ring over the polished area of the carrier shaft, being careful not to damage the polish.

The trick now is to form the steel air tube so that it wraps around the bearing cap and passes through the brass fitting that you have installed in the tapped hole. The tube must be very close to the bearing cap (touching is good) and close to the carrier (touching is not good). Once the tube is in place you can mark it even with top of the brass fitting, remove it and cut it off at the marked point.

Deburr the tube both inside and outside. Be sure that there are no chips or debris inside the tube.

Place one of the brass nipples on the end of the tube. The tube must extend at least ?" past the nipple.

Now lube the "O" rings and the polished shaft with light grease and install the slip ring. The trick here is to get the brass nipple to thread into the brass fitting in the housing and still have the tube in the right place. The compression sleeve can be slipped into the brass fitting in the housing (be sure that the tube passes all the way through the sleeve) then screw the compression nipple down onto the sleeve.

Before tightening the three screws that hold the slip ring on, be sure that the ring inside the ARB adjuster is centered so that the slip ring seats down flat against the adjuster. This part of the project is the most tedious and can be very frustrating. It is worth while to spend whatever time is required to do this part carefully as this is where most problems occur with Air Lockers.

Torque the bearing cap bolts to 72 ft. lb.

Recheck the backlash.

Don"t forget to replace the lock on the ring gear side adjuster.

Finishing Up

The air pump is very easy to install. Wiring is also very easy using the kit that is supplied by ARB.

Problems

The most common problems with the ARB Air Lockers are:

• "O" rings wear out because the carrier shaft is too rough.
• "O" rings are damaged at installation.
• The air fittings are not installed correctly. Compression sleeves must be all the way onto the tubes. No tape or sealer should be used on compression fittings.
• The plastic air lines get damaged. Be sure that the line to the housing is long enough so that it will not be stretched when the axle is at full droop. Do not pass the lines through holes with sharp edges. Do not place the lines next to anything hot (like exhaust pipes).