Outer Limits 4x4 Board

Replaced the rear locker in my 40 after the old one was damaged due to the pinion failing at Vic Winch this year.

The issue I had is the routing of the copper air feed for the locker inside the diff.

As you can see in the 2 pictures below the route of the copper air line has changed completely.





I could just be me but I could not put the diff in with the copper pipe situated far enough back so that it would clear the flange on the diff housing. My first attempt with the pipe in a position so it would pass inside the housing flange resulted in the copper pipe pushing against the back of the diff housing and rubbing on the crown wheel when fully located.

Luckily I suspected this was a possibility and checked carefully the rotation of the diff for any interference. You could hear it feel it and on removal see where it had gently rubbed.

Ideally you want the copper pipe to sit in centrally inside the diff housing for the best clearance. To achieve this though you have to bring the copper pipe forward of the position shown in the above pic. To where it is show on the ARB installation guide.

The issue I have is when you do this is, you can not put the diff in without having to tilt the diff and push the copper pipe down and under the housing flange as you fit it, allowing it to spring back into place after. There is no guarantee where the copper pipe springs back to and therefor how it sits in the diff. The length of the new pipe leaves it far more likely in my option to suffer with vibration over the old one.

To me this make is impossible to guarantee where the copper pipe finally sits in the diff and wether it will rub or not, it a little bit of lucky dip.

Anyone else had this issue or am I missing something here.

Why can't you drill and tap into the housing on the same side as the locker ring. There looks to be enough room there.

POS wrote:Why can't you drill and tap into the housing on the same side as the locker ring. There looks to be enough room there.

Not what ARB's manual shows and I don't think there is enough room with the crown wheel on that side, if there was I am sure ARB would have taken the easy option.

POS wrote:Why can't you drill and tap into the housing on the same side as the locker ring. There looks to be enough room there.

Yea why can't you. and put a plug in your old hole.

this was the biggest issue i had with the new design, my front copper line was torn in two, havnt takent he rear out yet (or plumbed it up) so not sure if it is still intact

Gday,

Matt,the way you have run the airline is not quite right.

i can't really describe how i would change it other than saying you have run the tube too high.

i would agree that it is very difficult to set the pipe up correctly without lots of experience fitting this new style of airlocker.

RD132(hilux) is the same but much worse because everything is smaller and even closer in the clearances.

RD135 & RD136 (nissan) run the tube through on the ring gear side but in my opinion there is not enough room to do it this way on your diff,or hilux diffs.

So that really only leaves you with the option of changing how you have routed the pipe.

Trust me there is a way.its just a bit scary!

dat383 wrote:Gday,

Matt,the way you have run the airline is not quite right.

i can't really describe how i would change it other than saying you have run the tube too high.

i would agree that it is very difficult to set the pipe up correctly without lots of experience fitting this new style of airlocker.

RD132(hilux) is the same but much worse because everything is smaller and even closer in the clearances.

RD135 & RD136 (nissan) run the tube through on the ring gear side but in my opinion there is not enough room to do it this way on your diff,or hilux diffs.

So that really only leaves you with the option of changing how you have routed the pipe.

Trust me there is a way.its just a bit scary!

I know there is a way, it's in and running but I don't like how I had to fit it, too many unknowns in my book.

I changed the pipe to more how ARB shows it to be rather than the photo above as it arrived from the diff specialist. But doing that makes it harder to fit.

I know what you mean.
The first few i did,i was thinking,how the hell is this going to work.
Like i said,try a hilux one,(rd132),they are much worse.esp.in a cruiser front.

drill in the spot you require and install the bulkhead fittings, plug the other side witha brass plug from any bunning plumbing section 1/4 inch npt bung iirc i have had to patch a hole to in mine upon a locker change.. use stag on the bung and allow setting time and u will be fine. =] and yes it is a bit of a lucky diip with the pipe , i destroyed one with my front locker trying to do it ont he ground at home insted of on a hoist at work , =[ disaster