ARB Locker Install: 2005 4Runner

[teotwaki]

Over a year ago I started down the path of building one of these into my 4Runner

I've always been very impressed with Toyota's A-Trac but I think that I have found some of the limitations where a locking diff would be the next step.

In March of 2008 I bought a lightly used 3rd member with an ARB that had 4:11 gears in it and thought it would be simple to get another set of stock gears. I don't plan to modify the front diff or go to larger tires for a while.

It took months to find stock gears. They are $900 new from a dealer. Most shops that perform gear changes just throw away stock gears for scrap. I managed to get a deal on a used 3rd member and it was shipped it to me clear across the country form the East Coast.

While I was searching for gears I purchased the ARB CKMA12 compressor and installed it between the fuse box and the master brake assembly

Two new switches in the lineup


Compressor bolted down with a red dust cap on the outlet

 

[teotwaki]

I worked with a shop called T&Js in Orange, California to build things for me. I basically wanted a complete 3rd member with the locker and stock gears. Then I could perform the swap into the axle myself as well as have my stock 3rd member as a spare. In May of 2009 it was complete with some new O-rings, a solid pinion spacer and the proper flange to mate to the driveshaft.

Nice & shiny ARB diff-3rd member


Then in June life got busy and this project sat on the shelf until December of '09

 

[daverami]

Looks great. Just put one in my 06 Tacoma with the same compressor. Where did you get the dust cap? If it came in the kit, they owe me one.

 

[teotwaki]

On January 1st, 2010 I pulled everything out and got to work.

After scouting out routes I decided to run the air line through the frame rail to get past the gas tank.

I used a long CB antenna as a "snake" coming from an outside hole in the frame behind the rear tire, going to a hole on the inside of the frame ahead of the gas tank.

I triple tie-wrapped the air line to it like this in order to pull it through


and pulled it though here


initially back to here


then I fed it back in to come out on the other side


To protect the blue tube from chafing on the frame I covered the tube with about two feet of 1/4" rubber fuel line

in the back


and up front


I removed the small heat shield that covered the fuel lines and routed the air hose up to the compressor



and plugged it into the solenoid's sir fitting (orange cap)


I leak tested all of the fittings and the compressor held air pressure over 22 minutes without cycling.

 

[teotwaki]

January2nd: getting ready at about 12 noon but no idea of what was in store for me!


Brake backing plate and axle pulled out as far as the lines will allow. Be sure to clean away all of the dirt before disassembly!
The speed sensor line's connector was full of dirt and had to be carefully cleaned out so that the release tab could be moved.
This is where the O-ring is that you have to be careful of positioning properly.


Stock diff with 100K miles on it


Diff housing ready for cleanup. Getting the old gasket off takes forever!!! Be sure to clean the rust off of the housing studs so that the new housing slides on easily.


If you ever pull a diff just go ahead and remove the anti-sway bar. Life will be much easier! Just put it back on before you re-attach the driveshaft.

The driveshaft flange has a raised cylindrical ridge on it that mates with the diff flange in order to center the driveshaft. If you are changing anything out, make sure yours fits together properly!! The one on my ARB diff was so beat up I had to get a Dremel tool to clean it up. I just hope I've not created a centering issue that will cause driveline balance problems. :-( Drive testing seems to be okay.

When you start to reattach the brake backing plates BE SURE that the O-ring is on the raised lip on the axle tube's flange!

 

[teotwaki]

I routed the final length of blue plastic air line along my extended breather line. I really needed to keep it away from the exhaust, protect it from snagging on any bushes I might ACCIDENTALLY run over as well as prevent any vertical pull when the axle is fully extended from the body.

 

[teotwaki]

By the way, the Yukon 4.11 Ring and Pinon are for sale or trade!

At TacoDocs recommendation I sold the extra 3rd member housing and carrier to East Coast gears.

 

[teotwaki]

Looks great. Just put one in my 06 Tacoma with the same compressor. Where did you get the dust cap? If it came in the kit, they owe me one.

The cap was just from the junk box in my garage. I think that it was a cover for a coaxial connector. I'll see if I have any more or if there is a manufacturer's name on it.

 

[daverami]

Thanks!

 

[dustboy]

Nice post, and clean routing of the air line. Now do the front!!:Wow1:

 

[teotwaki]

Nice post, and clean routing of the air line. Now do the front!!:Wow1:

Thanks! I need to go drive a bit with the rear locker and then evaluate the performance gain. If I see limits that a front locker would solve I'll look into that also. I've not paid much attention to a clamshell diff and the mechanics of installing a locker.

 

[Willman]

Clean work as always Jim!

I'm jealous!

Now time to break her in!

 

[teotwaki]

Clean work as always Jim!

I'm jealous!

Now time to break her in!

Thanks! I might have a chance to play a little bit tomorrow over at Cleghorn Road by Cajon Pass so I'll report on it if I do.

 

[teotwaki]

Went out for half a day to the Main Divide Truck Trail in the Cleveland National forest between Orange and Riverside Counties. Locker worked great!

Found this nice and gnarly downhill






Which I went down and then turned around and went back up it




I tried out a number of similar trails along the way and then at 1 PM headed back. At the first trail in the pictures I saw a Ford F-250 coming down and he got stuck pretty good at the bottom. Turns out he was 2WD with no locker and a broken winch. His right front tire is in a bottomless erosion channel. Left rear tire is in another big rut. If he went forward he'd go off the edge and he couldn't back up.

We strapped him up to my 4Runner and a good yank at a sharp left angle got him out.

 

[87FoRunner]

Sweet!


It's amazing how much of a difference lockers make on trucks. It is my favorite mod on my 4runner, and favorite option on my Tacoma.