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Re: Aussie Locker Installation [Re: justice] #969229 10/27/09 05:54 PM
Joined: Feb 2004
Posts: 10,238
FrankR Offline OP
Web Wheeler
****
Justice, if you look at one of the earlier pictures you can see where the circlip stops inside the spacer where the splines run out.

Actually, the spline engagement is about the same when you consider the .010" more slack in the axle end play, increased by the difference in chamfer length. It's probably slightly more spline engagement, but some of the engagement length is in the spacer - which isn't pinned to the axle gear.... it's just along for the ride.

All-in all, I think there's a little less spline engagement strength in the Aussie Locker. So, they are trying to get as much stregth as they can in a crowded location and I think it would not be wise to lengthen the chamfer.

Frank


'89 [color:"white"]G-Raider[color:"white"] [color:"black"]Supercharged 3.0L, MegaSquirt 2, lockup A/T, 2.5" exhaust, 172k, Cibie H4s/Oscar SCs, Hella Micro DE fogs, Cobra CB, Superwinch hubs, LSD rear/Aussie Locker front, Bilsteins, Lifeline AGM, Rust-Oleum
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Re: Aussie Locker Installation [Re: FrankR] #969230 10/27/09 06:33 PM
Joined: Feb 2000
Posts: 3,269
justice Offline
Roll Me Over
*****
Agreed.


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..
Re: Aussie Locker Installation [Re: justice] #969231 10/27/09 07:28 PM
Joined: Jan 2004
Posts: 918
motero Offline
Rock Warrior
If the splines on the spacer are not lined up with the splines on the side gear wouldn't that also be a hang up when reinserting the shaft?


99 Montero....15mpg! Sold (so sad)
02 Jetta TDI....48mpg!
03 2500 Ram QCLB Cummins....18mpg
02 2500 Yukon XL, We out grew the montero, at least it has one locker.....13mpg (sold)
01 montero limited
Re: Aussie Locker Installation [Re: motero] #969232 10/27/09 08:14 PM
Joined: Feb 2004
Posts: 10,238
FrankR Offline OP
Web Wheeler
****
No, the first need is to compress the circlip. After that, the axle and gear can be rotated to engage the spacer... if needed. It seemed to me that the spacer goes into position with no fiddling at all.

Frank


'89 [color:"white"]G-Raider[color:"white"] [color:"black"]Supercharged 3.0L, MegaSquirt 2, lockup A/T, 2.5" exhaust, 172k, Cibie H4s/Oscar SCs, Hella Micro DE fogs, Cobra CB, Superwinch hubs, LSD rear/Aussie Locker front, Bilsteins, Lifeline AGM, Rust-Oleum
Re: Aussie Locker Installation [Re: FrankR] #969233 10/27/09 08:43 PM
Joined: Aug 2005
Posts: 826
icysyrup Offline
Rock Warrior
My spacer needed to be lined up to get the shaft fully seated. I fiddled with it for 5 min till it finally went in easily, other than that it wasnt near the trouble you have had.


03 Montero XLS, OME 2"suspension lift,Full skid plates, Extended Diff/transfer breathers. 34 LTB's, Winch w/syn rope, Locked front/rear.
Re: Aussie Locker Installation [Re: icysyrup] #969234 10/27/09 10:19 PM
Joined: Feb 2004
Posts: 10,238
FrankR Offline OP
Web Wheeler
****
Did you remove the shock before you installed the axle? I suspect that's the biggest cause of my issue with the axle installation.

Frank


'89 [color:"white"]G-Raider[color:"white"] [color:"black"]Supercharged 3.0L, MegaSquirt 2, lockup A/T, 2.5" exhaust, 172k, Cibie H4s/Oscar SCs, Hella Micro DE fogs, Cobra CB, Superwinch hubs, LSD rear/Aussie Locker front, Bilsteins, Lifeline AGM, Rust-Oleum
Re: Aussie Locker Installation [Re: FrankR] #969235 10/28/09 06:22 AM
Joined: Aug 2005
Posts: 826
icysyrup Offline
Rock Warrior
Nope...didnt have to remove shock at all. I did have to undo the top ball joint in order to have easier access on drivers side. I suspect the Gen 3s might be a little different.


03 Montero XLS, OME 2"suspension lift,Full skid plates, Extended Diff/transfer breathers. 34 LTB's, Winch w/syn rope, Locked front/rear.
Re: Aussie Locker Installation [Re: icysyrup] #969236 10/29/09 01:51 AM
Joined: Aug 2009
Posts: 989
H
haztoys Offline
Rock Warrior
Great info Frank ... Thanks for the time and hard work to post the install ..

I buff the chamfer in all my installs ...Not cut just buff.. I think its a finish problem ... The mat finish that they do on the drop-in lockers is not a polish .. It seams to grab the ring ..

Have a good day

David

Hazardous Toys inc

Re: Aussie Locker Installation [Re: haztoys] #969237 10/29/09 08:54 PM
Joined: Feb 2004
Posts: 10,238
FrankR Offline OP
Web Wheeler
****
Finally! It's easy when you learn how to do it. <img src="/forums/images/graemlins/rolleyes.gif" alt="" /> Here's what I learned today that should apply to any Gen1:

It's not necessary to remove the shock. Grease the circlip and spline area. Turn the points of the circlip so they face downward and center the circlip on the axle. Holding it in your left hand (between the boots), insert the axle carefully so you don't lose the centering on the clip, rotate the axle slightly so you feel the splines in front of the clip engage the axle gear and bump the outer end of the axle hard with the heel of your right hand. It'll go right in. <img src="/forums/images/graemlins/smile.gif" alt="" /> The hard bump with the heel of a hand seems to have just the right amount of dead-blow force, where a plastic or rubber hammer will bounce and not fully compress the circlip.

BUT - it does hang up at the joint between the axle gear and the spacer - even if the splines are aligned. To force it all the way in, just pop it hard on the outer end with a plastic hammer and it'll go home as pretty as you please. <img src="/forums/images/graemlins/smile.gif" alt="" /> <img src="/forums/images/graemlins/smile.gif" alt="" />

I thought I should have a depth reference instead of guessing if the axle was inserted all the way, so I measured the dust cover depth to the carrier mounting bracket to get a reference. That dimension is about 0.925". I placed a piece of tape at the mark as an installation depth gauge:
[Linked Image]

Note that the mark is just about where the axle necks down, so there's no need to use a mark - just insert the axle until that necked-down area is at the edge of the carrier bracket. Here's the axle, fully inserted:
[Linked Image]

Driver side axle end play shimming is a little fiddly because the circlip will fool you as you pull the axle outward to check end play if the end play is small. The new axle gear doesn't stop the circlip as abrubtly as the OE axle gear. After installing a shim, checking, then adding another shim, I found the axle seemed to be creeping..... I was probably pulling too hard trying to feel the play. The best method is to initially install only the end clip, check the end play, select what you need for shims, remove the clip, install the shims + clip and re-check. Mine ended up at 0.018" - more than I'd like, but there's no shim (or combination) in the shim sets that can close the gap without getting too tight.... yours may - and likely will - be different.

Anyway, I'm done - it's all back together and full of gear oil. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Re: Aussie Locker Installation [Re: FrankR] #969238 02/22/10 01:33 AM
Joined: Feb 2004
Posts: 10,238
FrankR Offline OP
Web Wheeler
****
Tested the front Aussie Locker today - on pavement. It works fine and it's steerable, but just barely on pavement - and only at low speed. I didn't get a chance to try only one locked hub, but I would think that would make it much more functional on dry hard stuff.

Anyway, it wasn't a good test except to say that it does lock the front and makes almost no noise - barely perceptible click with standard lube. It works. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Frank


'89 [color:"white"]G-Raider[color:"white"] [color:"black"]Supercharged 3.0L, MegaSquirt 2, lockup A/T, 2.5" exhaust, 172k, Cibie H4s/Oscar SCs, Hella Micro DE fogs, Cobra CB, Superwinch hubs, LSD rear/Aussie Locker front, Bilsteins, Lifeline AGM, Rust-Oleum
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