ARB Dana 44 Air Locker Differential - 3.92 & Up, 30-Spline, RD116

ARB Installation Specifications:

• Ring Gear Bolt Torque - 3/8": 55 ft-lb (75 Nm)
• Ring Gear Bolt Torque - 7/16": 100 ft-lb (136 Nm)
• Ring Gear Bolt Torque - 1/2": 130 ft-lb (176 Nm)
• Ring & Pinion Backlash: 0.006"–0.010" (0.15–0.25mm)
• Bearing Cap Torque: 60 ft-lb (81 Nm), subject to vehicle manufacturer's specifications
• Minimum Alternate Air Supply Pressure: 85 PSI

Technical Note: ARB specifies RD117 for Dana 44 applications using 3.73-and-down gearing. Always follow the applicable ARB installation guide and vehicle manufacturer's service manual.

The ARB RD116 is designed for compatible Dana 44 axles with 30-spline axle shafts and 3.92-and-up gear ratios. The following table summarizes vehicle families represented in the supplied application data. Fitment is conditional on the actual installed axle assembly.

Important Fitment Notes:

• Requires compatible Dana 44 differential geometry and 30-spline axle shafts.
• Designed for 3.92-and-up gear ratios. For 3.73-and-down applications, refer to ARB RD117.
• Ring gear mounting bolts may be 3/8", 7/16", or 1/2" depending on the axle.
• For 7/16" bolts, ARB specifies enlarging the Air Locker flange holes to 11.5mm (29/64").
• For 1/2" bolts, ARB specifies enlarging the flange holes to 13.0mm (33/64").
• Applicable Ford Dana 44 IFS installations may require an additional axle-retention spring because the original C-clip cannot be reused.
• ARB identifies compatibility with an ABS tone ring where the axle application permits.
• Not all vehicles in the listed model families were factory-equipped with a compatible Dana 44.
• Verify axle identification, spline count, carrier break, ring gear dimensions, and ring gear bolt size before purchase.

What Dana 44 axles does the ARB RD116 Air Locker fit?

The RD116 fits compatible Dana 44 axles with 30-spline shafts and 3.92-and-up gear ratios. It can be used in front or rear applications when the carrier dimensions and ring gear mounting specifications match.

What is the difference between ARB RD116 and RD117?

The primary difference is gear ratio carrier compatibility. ARB RD116 is designed for Dana 44 3.92-and-up applications, while RD117 is specified for 3.73-and-down applications. Choosing the correct carrier is essential for proper ring gear installation.

Will the ARB RD116 fit a Jeep Wrangler TJ Dana 44?

Yes, for compatible 30-spline Dana 44 axle configurations with the correct carrier break. Verify the actual axle and ring gear specifications before ordering.

Can I use the RD116 in a front or rear Dana 44 axle?

Yes. The RD116 can be used in compatible front or rear Dana 44 assemblies. The axle shaft spline count, differential carrier configuration, and ring gear mounting dimensions must match the RD116 specifications.

Do I need to modify the ring gear mounting holes?

Possibly. Dana 44 ring gears may use 3/8", 7/16", or 1/2" mounting bolts. ARB specifies drilling or reaming the Air Locker flange to 11.5mm for 7/16" bolts or 13.0mm for 1/2" bolts. These modifications should be performed according to ARB's installation instructions.

Will the RD116 work with Ford Dana 44 independent front suspension?

Some Ford Dana 44 IFS configurations are supported, but additional installation work may be required. ARB notes that certain Ford IFS axle assemblies cannot reuse the original axle-retaining C-clip and require an alternative spring-retention arrangement.

Does the ARB RD116 require an air compressor?

Yes. The locker uses compressed air to activate the internal locking mechanism. A compatible ARB air compressor is recommended and sold separately.

Can the RD116 be used for everyday driving?

Yes. When disengaged, the differential operates as a conventional open differential, allowing normal wheel-speed differentiation during turns. The locker can be engaged when additional traction is needed, following ARB's operating instructions.

The ARB RD116 replaces the factory differential carrier with an air-actuated locking assembly. When activated, the internal clutch mechanism locks the axle shafts together, allowing both wheels to rotate at the same speed. When disengaged, the differential returns to normal open operation, making selectable traction useful for vehicles that transition between street driving and technical off-road terrain.

Ring Gear Bolt Compatibility: One of the most important installation details is matching the ring gear mounting hardware. Dana 44 applications may use 3/8", 7/16", or 1/2" bolts. The RD116 flange may require machining for the larger bolt sizes. ARB provides specific hole dimensions and ring gear torque specifications in the installation manual.

Carrier Setup: Proper carrier bearing preload, ring gear backlash, and seal housing positioning are critical to long-term reliability. ARB specifies 0.006"–0.010" backlash for the RD116 and provides detailed procedures for shimming the carrier and routing the internal air supply tube.

Ford IFS Applications: Certain Ford Dana 44 independent front suspension axles require special attention to axle shaft retention. ARB's installation manual describes an alternative spring-retention method where the original C-clip cannot be reused.

Builder Recommendation: Before installing the RD116, inspect the axle housing for straightness, confirm ring gear bolt dimensions, and check the condition of the existing bearings and gears. Proper air line routing, differential setup, and leak testing are just as important as selecting the correct locker. Professional differential installation is recommended.