TRE AIR LOCKER

Installation Manual

TR308
SUZUKI Grand Vitara FRONT
26 SPL, 12 Bolt RG
 CONTENTS

Introduction 3
Installation Preparation 4
A) Tool-Kit Recommendations 4
A-1 Tools 4
A-2 Supplies 4
` B) Remove the Original Differential 5
B-1 Support Vehicle by a hoist 5
B-2 Differential Fluid Drain 5
B-3 Removing the axles and Differential 5
B-4 Marking the Bearing Caps 5
B-5 Checking the Current Backlash Amount 6
B-6 Removing the Differential Carrier 7
C) Air locker installation 9
C-1 Mounting the Ring Gear 9
C-2 Installing the carrier bearings 10
C-3 Drilling and Tapping the Bulkhead Port 11
C-3-1 Drilling and Tapping For 5mm Air Line 11
C-3-2 Drilling and Tapping For 4mm Oil Return Line 12
C-4 Final Air Locker Assembly 13
C-5 Final Checking the Backlash 15
C-6 Installing the Seal Housing 16
C-7 Setting Up the Bulkhead Fitting 18
C-8 Profiling the Seal Housing Tube 20
C-9 Bench Testing the Air Locker 21
C-10 Reinstalling the Differential and Axles 22
D) Air System Installation 23
D-1 Mounting the Solenoid 23
D-2 Connection to Air Compressor 24
D-3 Running and Securing the 5mm Air Line and Oil Return Line 25
D-4 Connection to the Bulkhead Fitting (5mm Air Line) 26
D-5 Connection to the Bulkhead Fitting (4mm Oil return Line) 28
D-6 Mounting the Actuator Switch(es) 28
E) Mounting & Connecting the Electrical System 30
E-1 Mounting the Actuator Switch(es) 30
E-2 Wiring the Actuator System 30
F) Testing & Final Assembly 32
F-1 Leak Testing 32
F-2 Testing the Air Locker Actuation 32
F-3 Filling the Differential 33
F-4 Post-Installation Check List 33

Attention 35
Parts List 37
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 Introduction
TRE Air Locker designed for traction assistance. It's a driver-controlled differential

when additional traction is required. Driver turn on the control button Locking in both axle

deliver equal traction to wheels to providing 100% traction.

TRE Air Locker tested by various Pro 4x4 Races.

Available Terrain: snow, sand, muddy, rocky, etc.

Common use of TRE Air Locker

When you need more traction, turn on the air compressor first before get close to

extraordinary terrain, then turn on the Air Locker switch. (ATTENTION: Turn on the rear Air

Locker first, we don’t suggest you use front Air Locker alone) After passing, press the switch

again and the Air Locker will return to normal mode.

Do not turn on the Air Locker when the wheel is Idling, it will break the locking device.

When you turn off TRE Air Locker, the Air Locker is same as Differential, don’t worry

about any control problem .

Note: Place a ⓧ mark inside each of the ⃝ symbols as you complete each step. It

is very important NOT to miss any of the steps!

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 Installation Preparation
A) Tool-Kit Recommendations
Below is a list of tools and supplies you may need to complete this installation. Requirements for
your vehicle may vary. Please consult our vehicle service manual for additional recommendations.

A-1. Tools

⃝ Standard automotive sizes (metric and/or imperial) of sockets, wrenches, Allan keys, and
drills.
⃝ A dial indicator or other suitable measuring tool for checking ring &pinion backlash.
⃝ An adjuster-nut pliers
⃝ A razor knife to cut the nylon tubing.
⃝ A torque wrench (See vehicle service manual for required torque range.).
⃝ A lubricant drain reservoir.
⃝ An 11.2mm [7/16”] drill and ¼”NPT tap for bulkhead fitting installation.
⃝ An 8.5mm drill and ⅛” NPT tap for bulkhead fitting installation.
⃝ An automotive bearing puller or a differential carrier bearing puller.
⃝ A bearing press or arbor press.
⃝ A soft hammer(e.g. copper/rawhide/nylon etc.)

A-2. Supplies

⃝ Thread lubricant/sealant compound for pressure fittings. (e.g. LOCTITE #567Teflon paste)
⃝ Thread locking compound (e.g., LOCTITE #272)
⃝ Retaining compound (e.g. LOCTITE #609)
⃝ A gasket sealant or replacement gasket for your third member.
⃝ A sufficient volume of differential oil to completely refill your housing (see the TRE Air Locker
Operating and Service Manual for recommended lubricants)
⃝ A soap and water mixture to test for air leaks.
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B) Remove the Original Differential.

B-1. Support Vehicle by a hoist

B-2. Differential Fluid Drain

This is a good time to check for metal particles in your oil and in the bottom of the housing which
may indicate a worn bearing or differential component.

HINT : This is a good time to check for metal particles in your oil and in the bottom of the
housing which may indicate a worn bearing or differential component.

B-3. Removing the axles and Differential

⃝ Remove the axles according to your vehicle’s service manual.

HINT : When removing the axles try not to damage the paper gaskets behind the axle
flanges.

⃝ Disconnect the drive shaft from the flange of the differential.

⃝ Remove the third member from the differential housing. Refer to your vehicle’s service manual.

IMPORTANT:
TRE strongly recommends that you have your axle assembly inspected for concentricity
and straightness before installing your Air Locker.

B-4. Marking the Bearing Caps

⃝ Using a small pointed center punch, gently mark the bearing caps in a way that will enable you
to know which cap is ‘LEFT’ and which cap is ‘RIGHT’, which way is ‘ UP ’ and which way is
‘ DOWN ’.(Fig.1.)
⃝ Mark the right hand cap in a similar way.

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HINT : Many installers choose to make one punch mark on the left hand side of the left
hand bearing cap and a similar mark on the housing at close proximity to the cap
mark. The right hand side is then designated with two punch marks on the right
hand side of the cap and two similar punch marks on the housing

B-5. Checking the Current Backlash Amount

IMPORTANT:
This step is a precautionary measure recommended by TRE due to the fact that some aftermarket ring

and pinion sets have been manufactured to run with different backlash settings than those specified by

your vehicle manufacturer. Although TRE must recommend you set backlash according to your service

manual guidelines, we also advise that you compare the backlash measurements taken here to there

commended backlash settings in your vehicle service manual. Measurements found to be outside of

your service manual recommendations may indicate the need to deviate from those settings in order to

achieve quiet running with a good contact mark.

Refer to your vehicle service manual or your local authorized TRE installer for more information.

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⃝ Set a depth indicator on one of the ring gear teeth as in Figure2.

⃝ While supporting the pinion gear by holding the drive flange, rotate the differential in both
directions while observing the maximum variation in depth from the indicator (i.e., the highest
value minus the lowest value). This value is referred to as the ring and pinion backlash.
⃝ Rotate the differential center 90°and measure again for accuracy.
⃝ Record the average of all measurements.

B-6. Removing the Differential Carrier

⃝ Remove the adjuster nut locking tabs.
⃝ Remove the bearing caps from the third member.
⃝ Remove the adjuster nuts.
⃝ Carefully remove the differential carrier from the third member.
⃝ Remove the tapered roller bearings from the differential carrier with a bearing puller. (Fig.3.)

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HINT : Check the condition of the bearings for wear and replace if necessary.

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C) Air locker installation

C-1. Mounting the Ring Gear

⃝ Remove the bolts that hold the ring gear in place.
⃝ Using a plastic or copper hammer, tap in a circle around the ring gear to separate it from the
differential carrier
⃝ Thoroughly clean any thread locking compound or other foreign matter from the holes of the
ring gear, the threads of the ring gear bolts, and the mating surfaces of the ring gear and the
Air Locker flange.

IMPORTANT:
If the Air Locker is being installed in a Japanese model Jimny (i.e. JA12, JA22, JA71 & JB23) then the

provided ring gear spacer (190103) must be installed between the ring gear and the Air Locker.The

Japanese model Jimny can be identified by measuring the thickness between the ring gear flange and the

bolt face. It should be 7mm on the Japanese model and 4mm otherwise.

⃝ If required place the ring gear spacer (190103) onto the Air Locker.

NOTE : Rubbing the ring gear mounting face with a flat oil stone before installation will
remove any high spots around the threads.

⃝ Heat the ring gear to between 80 and 100°C (175- 212°F) in an oven or in hot water to
slightly expand the gear and facilitate assembly.

NOTE : NEVER HEAT GEARS WITH A FLAME! This could damage the hardened surface of
the gear and result in premature wear or failure.

⃝ Dry the ring gear with compressed air (if wet), paying particular attention to the threaded
holes.
⃝ Apply a thin film of high-pressure grease to the ring gear shoulder of the Air Locker to prevent

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 seizing
⃝ Install the ring gear onto the Air Locker by aligning the holes in the flange with the tapped
holes in the ring gear, then gently tapping it around in a circle with a plastic or copper
hammer.
⃝ Apply a thread locking compound to the thread of each ring gear bolt before inserting it.

NOTE : On some models, the crown wheel bolts cannot be reused and should therefore be
replaced. Refer to your vehicle manufacturer’s service manual for details.

⃝ Tighten the ring gear bolts in a star pattern with a torque wrench according to your vehicle
manufacturer’s specified torque.

C-2. Installing the Carrier Bearings

⃝ Apply a thin film of high pressure grease to the bearing journals of the Air Locker, then press
the bearing cones onto the bearing journals as shown in Figure5.

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C-3. Drilling and Tapping the Bulkhead Port

An air line port must be drilled and tapped through the Differential housing to mount the bulkhead
fitting into.(before drilling, the tube must be disassembled).

C-3-1. Drilling and Tapping the Bulkhead Port For 5mm Air Line

⃝ Mark a spot on the right hand side (opposite the ring gear) toward the top of the differential
housing that is in an area well clear of the differential, the ring gear, and any other
obstructions that could snag the seal housing tube. (Fig.6.)
⃝ Cover the drive pinion area with a rag to protect it from metal filings.
⃝ Secure the Differential housing to a work bench.
⃝ Drill an 11.2mm [7/16] diameter hole through the Tube square to the outside surface.(Fig7).

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⃝ Tap the hole from the outside using ¼”NPT thread tap.
⃝ Remove any sharp edges that may chip off from around the hole and fall into the tube.
⃝ Thoroughly clean the differential housing to remove any filings from drilling.

C-3-2. Drilling and Tapping the Bulkhead Port For 4mm Oil Return Line
An Oil return line port must be drilled and tapped through the differential housing to mount the
bulkhead fitting into Oil return line is designed for protect your air compressor from the
differential oil when disengage the air locker, and eliminate the differential loss.(this hole aim to
send the differential oil back)

⃝ Mark a spot on the right hand side (opposite the ring gear) toward the top of the differential
housing that is in an area well clear of the differential, the ring gear, and any other obstructions
that could snag the seal housing tube. This location should be beside the air line hole.

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⃝ Cover the drive pinion area with a rag to protect it from metal filings.
⃝ Secure the Differential housing to a work bench.
⃝ Drill an 8.6-8.7mm diameter hole(use a 8.5mm drill) through the housing square to the outside
surface.
⃝ Tap the hole from the outside using ⅛” NPT thread tap.
⃝ Remove any sharp edges that may chip off from around the hole and fall into the tube.
⃝ Thoroughly clean the differential housing to remove any filings from drilling.

C-4. Final Air Locker Assembly

⃝ Clean all parts of the differential assembly making sure it is free from any contaminants (e.g.,
dirt, water, metal fillings, etc.)
⃝ Holding the bearing cups in position, place the Air Locker into the differential housing and
install the bearing caps.

NOTE : Identify which sides the bearing caps are from, ensure they are on the correct
sides of the third member.

⃝ Pick the bearing cap on the case side and grind approximately 6mm off the sharp edge (Fig.8.),
to give enough clearance for the seal housing tube (Fig.9.)
⃝ Insert the bearing cap bolts and hand tighten.

Note : Before attempting to install the adjuster nuts, make sure the threads on the inside
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 of the bearing caps and differential housing are perfectly aligned. If they are not,
the threads could be stripped

⃝ Insert and lightly hand tighten the adjuster nut supplied with the Air Locker kit into the ring gear
side bearing cap

NOTE : You should feel no backlash between the ring and pinion gears once the adjuster
nut tightens.

⃝ Reverse the adjuster nut (counterclockwise) ¼ turn

⃝ Insert the original adjuster nut on the opposite side of the differential and tighten with the
appropriate adjuster nut wrench.

NOTE : You should now feel some backlash between the ring and pinion gears. If not,
there might be a clearance problem which is binding the carrier. Re-check the
clearance.

IMPORTANT:
When installing the Air Locker into the housing, it is critical to check for clearance between the Air Locker

case and the pinion gear. Some Japanese model Jimny have a larger pinion head and runs very close to

the Air Locker. Any less than 0.5mm [0.020 ” ] of clearance is inadequate, and the end of the pinion will

have to be modified.

⃝ Insert a feeler gauge between the case body and the pinion gear when the Air Locker is fully
seated onto the housing (Figure 10.).

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⃝ To prepare for pinion gear modification, cover the drive pinion area with a rag to protect it from
metal filings.
⃝ Use a 102mm [4.0 ”] or 127mm [5.0 ”] angle grinder and grind the ends of the pinion gear to a
30˚ angle at 1mm depth (Figure 11.).

⃝ Check clearance again using a feeler gauge and remove more material if required. The modified
pinion should look like figure 12.

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NOTE : Modifying the pinion gear in this way does not weaken the pinion at all.

C-5. Final Checking the Backlash

⃝ Set a depth indicator on one of the ring gear teeth (Fig.13.).
⃝ While supporting the pinion gear by holding the drive shaft flange, rotate the differential in
both directions while observing the maximum variation in depth from the indicator (i.e., the
highest value minus the lowest value). This value is referred to as the ring and pinion
backlash.
⃝ Rotate the differential center 90°and measure again for accuracy.
⃝ Refer to your vehicle service manual for the specified maximum and minimum amounts of
backlash.

IMPORTANT:
It is critical to set up bearing pre-load when a differential is installed. Improper pre-load will result in

undue bearing wear, increased stresses in the differential center, increased running noise, and ultimately,

ring and pinion gear damage

⃝ Adjust the backlash and pre-load using an adjuster nut wrench to tighten or loosen the adjuster
nuts as required. (Refer to your vehicle service manual.)
⃝ Recheck backlash as before, repeating this procedure until backlash is within the specified
amount.
⃝ Tighten the bearing cap bolts with a torque wrench to the torque specified in your vehicle
manufacturer’s service manual.

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C-6. Installing the Seal Housing
⃝ Make sure the grooves and airway of the seal housing are clean and free from any contaminants
(e.g. water, dirt, metal filings, etc.).
⃝ Inspect the seal housing O-rings (supplied) for dirt, damage or other conditions which might
cause leaks.
⃝ Generously lubricate the O-rings with oil prior to assembly, then insert them into the grooves of
the seal housing
NOTE : When assembling the O-rings, be careful not to leave them twisted when seated in
the grooves as this could cause excessive wear and leakage.

⃝ Lubricate the seal housing running surface on the Air Locker carrier with oil.
⃝ Carefully install the seal housing by sliding it all of the way onto the bearing journal with a
gentle twisting motion until it sits flat against the adjuster nut.

NOTE : A twisting motion (i.e., a slight rotation while pressing the seal housing on) will
allow the O-rings to engage gently and prevent them from twisting. Twisted
O-rings will result in pre-mature O-ring wear and oil contamination in the air
system due to the helical shape formed by the O-ring mould line.

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⃝ Rotate the seal housing until the square cutout lines up with the locking tab position at the
center of the bearing cap, and then assemble the locking tab. (Fig.14.) Ensure adequate
clearance between tab and cutout.

⃝ Install the spring clip by first hooking both ends of the clip into the small aligned cutouts of the
seal housing and the adjuster nut, and then snapping the clip into the groove of the seal
housing using a screw driver. (Fig.15.)

⃝ Check that the seal housing is now secured from rotating and that it is still sitting flat against the
adjuster nut.

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C-7. Setting up the Bulkhead Fitting
⃝ Apply thread sealant to the threads of the bulkhead body.
⃝ Screw the bulkhead body into the tapped hole, and tighten.
⃝ Wipe the area clean of any excess thread sealant (inside and outside of the housing).
⃝ Without using sharp, jagged tools such as pliers (your hands are the best tool for this job), bend
the seal housing tube on the outside of the housing to approximate the finished profile. This
will allow the tube to be trimmed to a length that would allow it to protrude from the bulkhead
fitting. (See Fig.16.) .

IMPORTANT:
The seal housing must still be able to freely float after the tube is connected to the bulkhead fitting.

Therefore, it is critical to ensure that the tube is not under any tension. To avoid this always leave the

tube long enough so that a hook shape can be formed between the seal housing and the bulkhead.

NOTE : Use an automotive brake line tubing cutter to cut the seal housing tube, never a
hacksaw as this will leave metal filings in the air system.

⃝ From the inside of the housing, insert the trimmed tube into the bulkhead.
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⃝ From the outside of the housing, assemble the small O-ring over the top of the short length of
seal housing tube protruding through the bulkhead fitting (Fig. 15.).

⃝ While holding the seal housing tube into the bulkhead fitting, insert the small drilled end of the
center compression nut over the extended tube as shown in the assembly diagram (Fig.16.),
and screw it into the bulkhead body, and lightly tighten.

NOTE : Excessive tightening of the center compression nut is not necessary to form a good
seal around the tube and may damage the O-ring, the seal housing tube, or the
threads of the compression nut.

NOTE : Make sure the seal housing tube is all of the way into the center compression nut
while you are tightening it.

C-8. Profiling the Seal Housing Tube

⃝ With the seal housing tube now firmly secured into the bulkhead fitting, bend the tube so that
it closely follows the profile of the differential. (Figs.19., 20.& 21.)
⃝ Check that the contour of the tube will not interfere with the bearing caps, the Air Locker or
the ring gear.

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- 21 -
 IMPORTANT:
In order for the seal housing to float and self center on the bearing journal, the seal housing tube must

not be pulling against the seal housing. To check this, rotate the drive flange back and forth while

observing the seal housing movement. The seal housing should rotate slightly against the spring clip, but

it should not appear to pull away from the face of the adjuster nut.

IMPORTANT:
Check that the tail of the adjuster nut locking tab does not push on the seal housing. Bend it up away

from the seal housing with a screw driver if necessary.

C-9. Bench Testing the Air Locker

⃝ To test the Air Locker; when 620kPa [90 PSI] shop air is applied to the seal housing tube, the
Air Locker should engage.
⃝ Check all fittings and the seal housing for air leaks.
⃝ Rotate the differential carrier by turning the pinion flange whilst applying air pressure.

NOTE : An accurate way to test for air leaks is to fit a shut-off valve to an air pressure
gauge. Once 620 KPA [90 PSI] is reached close the valve, disconnect the air hose,
and watch to see if there is any drop in pressure. If so, this will indicate an air
leak.(Fig.19.)

⃝ If a leak is found to be present, spray a soap and water mixture onto the bulkhead air fitting.
Bubbles should appear at any leak points.
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NOTE : Do not spray this soapy mixture inside the differential.

⃝ Check that leaky fittings have been adequately tightened.

⃝ Disassemble, clean threads, and reapply thread sealant if leaking persists.
⃝ If a leak is found at the seal housing, carefully remove the seal housing assembly and examine
the O-rings. Be very careful with the O-rings and check for defects, damage, wear, or presence
of foreign material in the O-ring grooves. Replace if necessary.

C-10. Reinstalling the Differential and Axles

⃝ Replace the paper gasket on the axle housing flange

⃝ Reinstall the third member to the differential housing according to your vehicle service manual.
⃝ Reinstall the drive shaft.
⃝ Replace the axle seals if necessary and fit to the axles.
⃝ Insert both axles fully into the housing, engaging splines, and then gently tap them inward.

NOTE : Be careful not to damage the axle shaft oil seals when installing the axle. Support the
axle’s entire weight where possible.

⃝ Torque down the axle bolts to manufacturer’s specifications

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D) Air System

D-1. Mounting the Solenoid

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D-2. Connection to Air Compressor

⃝ Remove one of the 1/8 ” BSP plugs from its port in the compressor tank.
⃝ Apply Teflon paste to the nipple (1/8 ” X 1/8 ” BSP) and insert it into the port and tighten.
⃝ Apply Teflon paste to the free end of the nipple.
⃝ Assemble the inlet port side of the solenoid (opposite arrow side) onto the nipple and tighten.
The solenoid should be rotated into a position that does not obstruct any other ports on the
compressor tank.

NOTE : The solenoid exhausts compressed air through the center of the black retaining
cap when the Air Locker is disengaged. Make sure this orifice cannot be obstructed
(the TRE equipped 4mm Oil return line should mount into the solenoid black
retaining cap hole)

⃝ Apply Teflon paste to the threads of the 5mm push-in fitting and assemble it into the solenoid
outlet port (arrow side) and tighten.

Note : Do not screw the plastic black part of the solenoid when mounting the solenoid.

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 IMPORTANT:
TRE cannot warrant your Air Locker(s) against damage caused as a result of using an alternate air

supply. If you have any doubts as to the suitability of your air system to use in an Air Locker system,

consult your TRE distributor.

D-3. Running and Securing the 5mm Air Line and 4mm Oil Return Line

The path taken by the air line from your air compressor to your Air Locker is unique to your vehicle
and the position of your air source. Plan ahead carefully when running the air line and always
follow these guidelines:

⃝ Account for axle travel when running the line from the axle to a fixed point on the vehicle.
Leave enough slack in the air line to allow for maximum suspension travel in both
directions.
⃝ Avoid leaving large lengths of air line hanging underneath the vehicle where they may get
tangled on rocks, sticks, etc.

HINT : Cable tying the air line to one of your flexible brake lines will account for axle travel
and should help keep your line from getting snagged.
⃝ Run the air line all the way from the compressor to the differential before trimming either end
of the line to length. This will save complications that may arise if the air line has to be
removed.
⃝ Make sure the line does not contact sharp edges or abrasive surfaces that may damage the air
line over time.
⃝ Do not run the air line around tight bends which may kink the air line and restrict or block the
air flow.
⃝ Keep the air line well away from your vehicle’s exhaust components. Air lines will melt if
subjected to extreme heat.
⃝ Do not run more air line than necessary. Excess line volume created when coiling the left over
hose, using unusually large diameter hose, etc., will increase drain on the compressor tank
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 resulting in the compressor running more often than needed.
⃝ Support the air line by tying it back with cable ties wherever possible.
⃝ At the solenoid end of the air line, trim the line to length with a sharp knife.

NOTE : To remove the air line from the push-in fitting; while holding the flange of the
fitting out, push the air line into the fitting as far as possible, then press the flange
inward, then pull the air line free of the fitting

⃝ To attach the air line to the push-in fitting of the solenoid; insert the line firmly into the fitting,
pull outward on the flange of the fitting while holding the line as far into the fitting as
possible, and then gently pull outward on the air line to clamp the line in place.

D-4. Connection to the Bulkhead Fitting(5mm Air Line)

⃝ Trim the air line to length using a sharp knife.
⃝ Insert the support spring over the end of the air line - small end first. (Fig. 24.)
⃝ Insert the outer compression nut over the air line.
⃝ Push the air line onto the barb on the center compression nut, ensuring that it is pushed all the
way to the end.

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HINT : If the tube is too difficult to push on, place the end of the air line into a cup of
boiled water to soften the tubing.

⃝ Screw on the outer compression nut and tighten, while supporting the center compression nut
with a 3/8” spanner. The airline is now attached to the center compression nut.

NOTE : The outer compression nut will tighten against a stop. Over tightening will not
create a better seal.

⃝ Assemble the support spring over the outside of the outer compression nut.
⃝ Secure any loose sections of tube with a cable tie

D-5. Connection to the Bulkhead Fitting (4mm Oil return Line)

⃝ Screw the blue interface bulkhead fitting on the mark of 4mm oil return hole on the differential
case and tighten.
⃝ Trim the air line to length using a sharp knife.

HINT : If the tube is too difficult to push on, place the end of the air line into a cup of
boiled water to soften the tubing.
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⃝ Connect the 4mm air line to the blue interface bulkhead fitting from solenoid.
⃝ Secure any loose sections of tube with a cable tie.

D-6. Mounting the Actuator Switch(es)

Air Locker actuator switch(es) can be easily panel mounted inside the vehicle in a 21mm x 36.5mm
[0.83 ” x 1.44 ” ] rectangular cutout.

NOTE : Only attach the cover plate to the face of the switch once the switch has been
mounted and wired correctly as the cover plates are designed to be difficult to
remove.
For reasons of safety and for ease of operation, the Air Locker actuator switch(es) should be
mounted in a location picked to best suit the operator. Make sure you have taken the following
points into consideration:
⃝ Switch (es) MUST be mounted and should never be allowed to simply dangle from the wiring
loom during vehicle use.
⃝ Switch(es) should be within easy reach of the driver. Ideally, any Air Locker switch should be
able to be operated without physical effort or distraction to the driver.
⃝ Switch(es) should be mounted within the line of sight of the driver so that switch position
(‘ ON ’ or ‘ OFF ’ ) can be visually determined by the rocker position and the illumination state.
⃝ The position of the switch(es) should best eliminate any possibility of accidental operation by
the driver or one of the passengers.
⃝ Switch cutout position(s) must be located in an area with a minimum of 50mm [2 ” ] of
clearance behind the face of the cutout.
⃝ Switch(es) should not be mounted where they will be exposed to water (e.g., in the lower
section of an inner door panel).

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E) Mounting & Connecting the Electrical System

E-1. Wiring the Actuator System

E-2. Connection to an Air Compressor

When wiring the Air Locker actuator switch(es) and solenoid(s) to an TRE Air Compressor, all
connections can easily be set up directly from the supplied wiring loom

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- 31 -
F) Testing & Final Assembly

F-1. Leak Testing

⃝ With the vehicle parked and the engine off, turn the compressor on and wait until the air
system is fully charged.

NOTE : With the Air Locker(s) disengaged, the air compressor should not have to recharge
over time. Intermittent recharging without Air Locker use usually indicates a leak
at the solenoid fittings or at the compressor tank O-ring seal.

⃝ Actuate the Air Locker(s).

⃝ The compressor should not come on again for a rapid period. Air system recharging within
that time period would indicate that a leak is present in the system.
⃝ If a leak is found to be present, spray a soap and water mixture onto all air fittings in the
system while the compressor is fully charged. Bubbles should appear at any leak points.
⃝ Check that leaky fittings have been adequately tightened.
⃝ Disassemble, clean threads, and reapply thread sealant if leaking persists.

F-2. Testing the Air Locker Actuation

To test that your air system, electrical system, and your Air Locker differential is functioning
correctly:
⃝ Support the vehicle such that the wheels are free to rotate (e.g., on axle stands , a chassis
hoist, etc.)
⃝ Leave the parking brake off, the transmission in neutral, and the Air Locker switch ‘ OFF ’ .
⃝ Turn the ignition to the ‘ ON ’ position (leaving the motor off). The large illuminating symbol
on the Air Locker switch cover should be ‘ OFF ’ .
⃝ Turn the compressor (or alternate air source) on to charge the air supply up to its maximum
pressure.
⃝ Rotate one wheel by hand.
⃝ The wheel should rotate freely and the opposite wheel should be turning in the opposite
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 direction without any resistance or mechanical noise from within the differential.
⃝ Turn the Air Locker switch to the ‘ ON ’ position. The illuminated symbol on the switch cover
should light up.
⃝ Rotate the same wheel again.
⃝ Both wheels should rotate together.
⃝ Turn the switch off again.
⃝ Rotate the same wheel.
⃝ The wheels should again rotate in opposite directions

F-3. Filling the Differential

NOTE : Consult the TRE Air Locker Operating & Service Manual for recommendations on
differential lubricant specifications.

⃝ Refill the differential until level with the filler hole.

⃝ Rotate the differential center 2 full turns.
⃝ Check the oil level and add oil if necessary.
⃝ Replace filler plug (apply thread sealant to filler plug before inserting if it is a threaded type
plug).
⃝ Wipe differential housing clean of any oil or grease which may collect dirt or other abrasive
Particles.

F-4. Post-Installation Check List

Now that the Air Locker installation has been completed, TRE recommends that you take the time
to complete the following check list just to insure that you haven’t missed any of the vital steps.
⃝ The air system has been leak tested.
⃝ Thread locking compound was used on the ring gear bolts.
⃝ All torque settings comply with the vehicle manufacturer’s specs and were set with an
accurate torque wrench.
⃝ Differential fluid complies with TRE recommendations and has been filled to the correct level.
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⃝ All air lines and wiring have been securely cable tied to resist snagging.
⃝ Switch(es) have been securely mounted within operator reach, yet well away from danger of
accidental engagement.
⃝ Switch(es) function properly and illuminate to indicate that Air Locker(s) are engaged.
⃝ All operators who are to use the Air Locker have read, and fully understand the TRE Air Locker
Operating & Service Manual.

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 ATTENTION

For the safety of vehicles and occupants, there are several points that must be understood
and complied with:

1、When driving at high speed on high traction pavement (IE: dry pavement, cement pavement,
asphalt pavement, gravel pavement, etc.)The differential locking device has great damage to
the transmission components and may cause an accident. The locking device can only be
turned on when the road surface with high traction is required.

2、Turn on the differential lock will affect the steering. User should cost time to understand how
the differential will affect the steering. Otherwise, if you don't understand it, you can not use it
rashly, which may put you and the occupants at risk.

3、The switch should be installed in the proper range of the driver, but must ensure that the
switch will not be accidentally touched by the driver, the occupant or the object loosened in
the car, accidental turn on, or turn off will cause the vehicle out of control.

4、When in use, the independent switch can avoid the unnecessary work of the air pump. To
avoid accidental turn on the differential locker , the differential locker switch should be turned
off when not in use. Do not use a independent air pump switch to simultaneously control the
locking device. The air pump switch must be used separately.

5、Although the stable and quality of the TRE differential lock is very strong, the locking device
should not be turn on when the wheel is idling. Otherwise, the impact force generated when
the two wheels are suddenly forced to rotate at the same speed may cause the half shaft be
damaged , locking part worn. When turning on the locking device, make sure that the vehicle
in a stopped state , is not activated or decelerated. Do not turn on the locking device when
turning, do not turn on the locking device while braking.

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6、In order to reduce the damage to the vehicle transmission system and reduce the risk of
vehicle control, the speed should be reduced when turning on the locking device，slowly and
skillfully off-road driving to achieve the best years of vehicle use

7、Do not make sharp turns after locking the differential . Especially when the front and rear locks
are locked at the same time, keep the straight line as much as possible. Otherwise, it is easy to
twist the half shaft or Differential.

8、If the locking device is not used frequently, it will produce oil film. Please test it .

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 PART LIST

Air Locker model: TR308

SUZUKI Grand Vitara FRONT 26 SPL, 12 Bolt RG

1. Exploded Assembly diagram

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2. Component List

MODEL No. : TR308

ITEM # QTY DESCRIPTION NOTES #
01 1 FLANGE CAP ASSEMBLY
02 1 BONDED SEAL
03 1 CLUTCH GEAR
04 2 SHORT CROSS SHAFT
05 1 LONG CROSS SHAFT
06 1 SIDE GEAR
07 2 SIDE GEAR THRUST WASHER
08 2 COUNTERSUNK SCREW
09 3 RETAINING PIN
10 - TAPERED ROLLER BEARING NOT SUPPLIED
11 1 SEAL HOUSING RETAINING CLIP
12 1 SEAL HOUSING ASSEMBLY
13 2 SEAL HOUSING O-RINGS
14 1 ADJUSTER NUT
15 10 RETURN SPRINGS
16 1 SPLINED SIDE GEAR
17 4 PINION GEAR
18 4 PINION THRUST WASHER
19 1 SPIDER BLOCK
20 1 DIFFERENTIAL CASE
* 1 BULKHEAD KIT, O-RING TYPE
* 1 PUSH-IN FITTING (5mm to 1/8”BSPP)
* 1 NIPPLE (1/8” to 1/8” BSPT)
* 1 AIR LINE (5mm Dia X 6m long)
* 1 OIL RETURN LINE (4mm Dia X 6m long)
* 1 SOLENOID VALVE (12V)
* 1 ON/OFF SWITCH
* 1 SWITCH COVER ‘FRONT’
* 1 SWITCH COVER ‘REAR’
* 10 CABLE TIE
* 1 RHINO STICKER
* 1 TRE 4X4 BROCHURE
* 1 WARRANTY CARD
* 1 INSTALLATION MANUAL

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