Ruin Cody's day in 3...2...1... (rear locker?)

[azzzuki]

Originally Posted by gearinstalls.com

Cody is gonna come over when he gets a chance and we will probably remove the 3rd. This one has the older round o-rings but I expect that is ok. I'm thinking rub-thru. Here's the link I did on Cody's 3rd
gear install
The ARB RD124 instruction manual was not in the box and the only thing I wanted to see in it was the suggested routing of the copper line. You can see in Cody's link, near the very end, that I used a large service loop....nicely routed and close to the case but clearanced good. we'll just have to see. ZUK


azzzuki
Hey cody; I cant belive u got dave to set up yr gears.....When i ask him last year to set up mine he said NO!....
.Im sure u wil figger out the leak...

Sorry Rob......once I realized that my tooling and pullers would have no issues, I then started taking the LC stuff.

Im sorry to, after i met u on yr trip home from Moab here in Flg....All this time i thought yr name was Dave.
Ken, i should have u redo my geas because the guy who set them up dint do a good job and now i got lots of backlash.....what do ya charge?


Rob

[cruzer971]

I think your supposed to apologize when you hijack somebody's thread

[decavo]

My Arb's acted like that/ I refilled with gear oil checked for leaks etc... I would engage it on a slow roll It finally started working again and I have had no problems since if you cycle the locker switch a few time it will engage.. and using the arb's frequently keeps them working.. I flip mine on weekly and drive down a dirt road.. My problem was lack of use.. My problem started a few weeks after install also.

[CodyRx7]

I'm really not sure what the diff being full.....or completely empty of fluid would have to do with the ARB air locker.

If you can bench test the 3rd outside of the axle housing, add air pressure to engage the locker and verify there are no air leaks...the diff fluid should not come into play at all.

It is an air locker....not a fluid locker afterall, right?

Anyhow...I went out today to check the hose connections again...no leaks in that area, but the compressor on and locker switch on......air is still rushing out of the axle breather.

I undid the hose nut and removed the hose.

I undid the little male-male connection between the hose and the female connection on top of the housing.

The copper line is still present and the O-ring is there still looking brand new. (its a bad picture, kinda hard to get my camera in there and focus properly)



Looks like I'll be makin a trip down to ZUK's place so we can pull it all apart and figure out if its a copper tubing seperation or hole somewhere inside...or if the seal assembly or O-rings inside of it are dead.

[chappysfj40]

Originally Posted by The Proton

I had the same thing happen in my ARB equipped Samurai 4 months after professional installation. The shop took it back no questions asked and fixed it, it was the O-Ring. I also had the pleasure of Gear Oil shooting out of the solonoid on the compressor when I flicked the switch

Worked fine ever since (6+ years)

So if i have alittle fluid coming out of my solonid too then i have a bad o ring also. so i need to pay close attention to this thread it looks like.
thanks

[24HOURSOFNEVADA]

Originally Posted by gearinstalls.com

Cody is gonna come over when he gets a chance and we will probably remove the 3rd. This one has the older round o-rings but I expect that is ok. I'm thinking rub-thru. Here's the link I did on Cody's 3rd
gear install
The ARB RD124 instruction manual was not in the box and the only thing I wanted to see in it was the suggested routing of the copper line. You can see in Cody's link, near the very end, that I used a large service loop....nicely routed and close to the case but clearanced good. we'll just have to see. ZUK


azzzuki
Hey cody; I cant belive u got dave to set up yr gears.....When i ask him last year to set up mine he said NO!....
.Im sure u wil figger out the leak...

Sorry Rob......once I realized that my tooling and pullers would have no issues, I then started taking the LC stuff.

With a gear write up/install like that I'd say everything is going to be taken care of. I'd have no problem having him do my gear set ups.

[gearinstalls.com]

It's 11:10pm and Cody just left.....the ARB was missing the retainer bolt that holds in the cross-pin...that is a rare occurrance.....it was never there and I never noticed it missing because that hole was on the bottom side of the ARB when I was installing it. Anyways, with no retainer, the cross-pin worked its way out and then shredded the copper air line. The 529 ring and pinion escaped damage. Cody is going to call JT's on Tuesday....I'm sure Carl or Jeremy will have another here in no time. Here's some pics of what we found....

The shredded copper line....


Here's the cross-pin that wiggled its way out and hit the copper line as well as banged into the pinion teeth edges....no real damage to the pinion teeth....cosmetic.


Here's the other side of the cross-pin that started to drop in....




Here's the rest of the copper line to the bulk fitting


Here's the pinion...teeth are good...some rounding on the edges but the teeth never make any contact there so all is good....lots of copper paste seen in the carrier...



Here's where the long retainer bolt would normally be. Add this to my list of things to check from now on when I install ARB's


So I swapped over the 529 ring to Cody's old open case and that will allow him to drive it for now.

[gearinstalls.com]

Looking at the actual pics in the link I did for Cody, I see one pic of the freshly unwrapped ARB.... and you can see half the hole where a retainer bolt should be ....I told Cody to buy a lottery ticket...this is some kind of luck. Stuff happens....even at the ARB factory. ZUK

[-Spike-]

It's incredible that you have a pic of the carrier freshly unpackaged, and the empty bolt hole. Let us know if ARB steps up to the plate re: R&R costs.

-Spike

[CodyRx7]

Just got in...

Awesome that the pic is there for proof, ZUK, if its needed at all.

It was somewhat of a blessing in disguise that I noticed the air leaking into the housing and the compressor not shutting off... If that pin managed work work its way out, I'm sure the damage could have been a lot worse and probably much harder if not impossible to pinpoint the cause with the carnage.

[Cruiserdrew]

Wow--You dodged a bullet. If that shaft had come out, the whole thing would have self destructed likely locking the diff at speed. That could have been much worse.

[cruzer971]

Well that makes me feel a lot better. I thought there was a chance that it was something I did when we put it in. Hope you get it all going by this weekend.

[Tapage]

Originally Posted by Cruiserdrew

Wow--You dodged a bullet. If that shaft had come out, the whole thing would have self destructed likely locking the diff at speed. That could have been much worse.

Lucky guy .. that the cross pin only move a few milimeters ..

[bluecruiser]

ZUK is an awesome, stand-up guy....he did the ARB install on my 100. Very meticulous and his write-ups show it....

glad you guys got this figured out...it will be interesting if ARB steps up for some RR costs (like SPIKE said)....

[CodyRx7]

I really do have to commend ZUK here.

I can't think of any shops or mechanics I have ever dealt with who would be willing to invite me to their house, rearrange their driveway and yank out buckets, extension cords and handfuls of tools, tear apart a vehicle and put it back together at 11pm on a Saturday night...

On top of all that he had already "gone fishin" for the Summer as temps in his shop can be quite uncomfortable.

I'll gladly recommend ZUK and GearInstalls.com for anyone needing new gears or lockers installed.

[concretejungle]

Originally Posted by CodyRx7

I really do have to commend ZUK here.

I can't think of any shops or mechanics I have ever dealt with who would be willing to invite me to their house, rearrange their driveway and yank out buckets, extension cords and handfuls of tools, tear apart a vehicle and put it back together at 11pm on a Saturday night...

On top of all that he had already "gone fishin" for the Summer as temps in his shop can be quite uncomfortable.

I'll gladly recommend ZUK and GearInstalls.com for anyone needing new gears or lockers installed.

No doubt!! I will be air mailing him my chunks when i get new gears and ARBs

[BenMara]

Originally Posted by concretejungle

No doubt!! I will be air mailing him my chunks when i get new gears and ARBs

same here in due time

[Leroy]

Originally Posted by concretejungle

No doubt!! I will be air mailing him my chunks when i get new gears and ARBs

absolutely. this kind of honest, forthcoming and conclusive post gives any potential customer a lot a faith. solid.

[gearinstalls.com]

Originally Posted by CodyRx7

.................................................. .....
.................................................. .....................It was somewhat of a blessing in disguise that I noticed the air leaking into the housing and the compressor not shutting off... If that pin managed work work its way out, I'm sure the damage could have been a lot worse............................................. .......

I agree....the crosspin had worked its way out only about 1/4"(6mm) and was already contacting the tips of the pinion teeth....one or 2 chips from the pin were found in the oil as it was. Bigger chunks might have gotten caught in the ring and pinion and chipped the ring resulting in more expense.
Thanks for the kind words....ya, it's getting to be summer here so I am taking the usual fishing break but will be available as the mornings cool down in the fall. In the meantime, you all know that not only can JTs Parts & Accessories, Justdifferentials.com supply the quality ring/pinions/install kits but they also have a gear install bench.....and do a good job....just so you know

Cody- Just forgot to ask you about those monster 39" tires and how much better the 529 gears must be compared to the old 410 ratio? You had mentioned your mileage went up when you were over here but how is the acceleration now?
Did you contact JT's yet?
ZUK

[CodyRx7]

Just got off the phone with JTs. I mentioned we had pictures of the damage and evidence of the missing crosspin securing bolt from the factory.

He wanted me to send him an email link to the pictures, so I sent him post 37 and 38.

He's supposed to review the pictures and let me know the options available.

He did mention maybe ARB would just send out replacement pieces for the damaged ones...like new crosspins and retaining bolts...

I'm hoping they actually want to replace the whole unit since I need a new air seal assembly and who knows if there are any internal damages to the locker?

- - - - -

As far as the 5.29 over 4.10 improvement, acceleration is greatly improved. I had to have the "POWER" button engaged on the transmission 100% of the time before or else it felt like I was towing a 10,000lb trailer behind me. Now I can run around town comfortably without the POWER button on, and only use it on the long I-17 incline grades.

I filled the gas tank up here in PV before I drove down to ZUK's in Chandler. According to Google Maps thats a 116 mile trip.

Round trip 232 miles, and the low fuel light was just flickering on as I pulled into my subdivision.

Just by guesstimates, my light comes on when I have about 7 gallons of fuel left (based on what I can add to top off the 25 gallon tank)

So 18 gallons of fuel for 232 miles = 12.8 mpg.

Not bad, considering Phoenix to Prescott Valley is almost all uphill. :P

I averaged about 8 city, 10 highway mpg with the 39" tires and 4.10 gears before.

[CodyRx7]

REPLY from JT:

I just got off the phone with tech @ ARB. The cross pin shaft on the RD124 is retained with a pin and a bolt. These two items do not come installed in the air locker. They actually come loose in a little plastic baggy along with other small items such as a c-clip kit which is not applicable to your 80 series. ARB has agreed to take of this and they are sending the necessary parts to get you back in action again. But I would imagine that the pin & bolt are there somewhere and just not being used.

I saw the C-Clip parts and ZUK explained those weren't for mine since I don't have a Cclip axle...there was no other long bolt in a baggy, and I can't see why ARB would not have that part installed and have it supposedly seperate?

[CodyRx7]

Quote I found from an ARB PDF:

NOTE: If the Air Locker is being installed into a non-C clip housing than the cross shaft may not need to be removed, however, the cross shaft pin retaining screw (supplied) will still need to have a thread locking compound applied and be installed into the Air Locker and tightened before final assembly (see Section 4.12 Reinstalling the Axles)

[CodyRx7]

Not calling anyone out here....but I do have concern.

Anyone know if the front ARB on my 80 series has the same retaining bolt used for the crosspin?

While I definately wouldn't want the rear locking in place, I sure as hell wouldn't want the front axle to lock in place at speed...

[gearinstalls.com]

Your front is ok Cody...rest easy.....see the pic. After I showed you that bag of c-clips, I ended up throwing it away. I don't remember a bolt in there but I'm not sure now. In any event, I'm glad ARB is sending the repair stuff. I can work with that.

[gearinstalls.com]

Thank you ARB for sending the replacement parts
Cody just left with a ready to go ARB 9.5" rear 3rd.
Here's some pics...

They sent a new pin....


We wanted to make sure nothing else was effected inside....


...so we carefully removed things after the old cross-pin was clear.


All looked good so time to put the new pin in.


The missing roll-pin is now carefully inserted...these are not hardened steel...they are a very soft metal...easy to bend them up.


Loctite on the bolt threads.


Tightened up and good to go. The ring gear was moved over...CBPL and BL were set as before and the new seal assembly that ARB sent with the new copper line was routed and done. Cody is on his way home now to mount the 3rd up. ZUK

[concretejungle]

i love a happy ending!