Hilux 4x4 Forum

I was out playing around a few weeks ago and went to engage my diff locks for a rather challenging climb. (I have ARB RD01 air lockers fitted front and rear)
Rear engaged no problem, but as I flicked the switch for the front locker, whooosh, all the air pressure dropped in the system and the compressor kicked in, but could not
maintain pressure. I then checked and found the air blowing out my extended diff breather....

So on getting home I had to face the fact that I had to remove the front diff, and for those who have done it, it's a big job on an SFA.
Anyway, youtube provided a quicker way to pull the steering knuckles off without complete dissasembly and remove the sideshafts / birfields.
If you need info on stripping the front axle, look here at my axle rebuild post:
viewtopic.php?f=92&t=9011

and also here:
How to Remove a Birfield Joint (The fast way) aka The Camo Method Toyota 4x4 Solid Axle by WheeliePete
https://www.youtube.com/watch?v=o3Y5bQGiezY

So here it started...

After pulling the front diff out, I found the problem.
The rotary air seal end cap unit had popped the o-ring out, causing all the air to escape when pressurised at 6 bar...
On looking at the installation manual, I found the retaining clip missing. Further searching revealed it had come off and ended up in the axle housing.
Thankfully it did not go through the diff gears

This is the missing clip, and this is where it fits in to the locker assembly
I still cannot determine why it unclipped ...

Here the air end rotary unit removed (not my picture, I forgot to take one) showing the o-ring grooves. My o-rings were now suspect, so I had to get new ones.

In replacing the o-rings, I scoured the interweb for the spec, not wanting to pay ARB part number prices
I have the ARB RD01 air lockers installed, my install manual lists an incorrect part number as I discovered.
The correct part number from ARB for the o-rings is 160205. Luckily I managed to find the equivalent part table chart
for the o-rings from ARB.

ARB part number: 160205
Standard part number: BS132V75 ---> 44.12mm ID 2.62mm CS Viton

Got them from Bearing Man (BMG) for R 10ea

Cleaned everything up (and a bit of rust due to lack of use...) and lubricated the new o-rings in clean diff ol and refitted everything.

I made sure the retaining clip was well seated and cannot move
Did a pressure test for 1 hour, no leaks!!!!

With all that done, I re-fitted the diff and re-assembled the axle (about 5 hours work)

(I also replace the pinion oil seal while I was doing this job and fitted a new locking nut which I did not cover in this post)
I also re-fitted the Aisin front locking hubs which i serviced and repainted. Look a bit better
Took the Lux for a good drive and every is working as it should!!

Sorry t hear of your woes Andrew, but thanks for yet another informative post. Glad you got it sorted!

Mud Dog wrote: ↑Tue Jul 04, 2017 6:06 pm Sorry t hear of your woes Andrew, but thanks for yet another informative post. Glad you got it sorted!

Joh, been a while Andy. Finally getting some time again to play with my Hilux. Thought I'd contribute some of my learnings again lol.

Good post thanks.