4x4Wire TrailTalk

Aussie Locker Installation

Posted By: FrankR

Aussie Locker Installation - 10/22/09 11:51 PM

I installed my front Aussie Locker today and thought I'd post this as a guide for anyone who follows. This is the first time I've done this job, so if anyone sees an error, please let me and those who read this know:

First, some preliminaries that I'll assume anyone trying this already knows how to do:

1) Drain the gear oil
2) Remove the front differential cover
3) Remove the tires
4) Remove the brake calipers and hang them
5) Remove the hubs
6) Remove the steering knuckles
7) Remove the drive axles
8) Withdraw the passenger side inner axle about 6 inches
9) Remove the relay rod

Now you're looking at this, but note that it's not necessary to unbolt the inner axle tube as I did <img src="/forums/images/graemlins/rolleyes.gif" alt="" />:
[Linked Image]

Loosen the four bolts pictured above and remove the bearing caps - note which side they came from and which end is up for re-installation in the same location. Now you see what's under each cap - the outer bearing race - and a side bearing adjusting spacer is to the outside of each cap/race:
[Linked Image]

Carefully pry out the differential case assembly - the FSM shows the use of 2 hammer handles, but that's only feasible if you have the differential carrier completely removed from the truck - perhaps I should have removed the carrier and put the entire assembly on the workbench, but I thought it might be easier like this - more on that later. Be very careful as the unit gets loose enough to come out - it's heavy and it is very important to capture the side bearing adjusting spacers and side bearing outer races so you know which one of each goes back on which side::
[Linked Image]

Now you can take the case assembly to the workbench - again, keeping the bearing caps, spacers and outer races separate:
[Linked Image]

There are a lot of pictures, so I'll break this up in several posts.

Frank
Posted By: FrankR

Re: Aussie Locker Installation - 10/23/09 12:06 AM

Mark the ring gear and differential case flange edge with mating marks so you know where to clock the gear on reassembly:
[Linked Image]

For ring gear removal, the use of an impact wrench is almost a necessity, but it can be done in a vise with hand tools. Remove the ring gear and you have this:
[Linked Image]

This lock pin holds the pinion shaft and must be driven far enough to clear the shaft - don't drive it all the way out - just far enough to clear the shaft:
[Linked Image]

Now you have this:
[Linked Image]

Frank
Posted By: FrankR

Re: Aussie Locker Installation - 10/23/09 12:23 AM

Drive out the pinion shaft. Pull out the upper and lower pinion gears and cupped pinion washers and you have this:
[Linked Image]

Pull out the side gears and note that each gear has a thrust spacer behind it - those will be used later - for now, examine them closely.... if they're worn much, get new ones - because they will affect your center gap on the Aussie Locker, which could void your warranty. Mine show very little wear, so I'll reuse them and check the gap after the locker is installed:
[Linked Image]

Completely grease all surfaces of an axle gear from the kit and install it using the thrust spacer in the previous picture:
[Linked Image]

Grease a spacer, note which way it's oriented and place it on top of the gear:
[Linked Image]

Grease a cam gear, orient it with the half-bore toward the center of the case and place it on the stack - press the stack to squeeze out the excess grease:
[Linked Image]

Frank
Posted By: FrankR

Re: Aussie Locker Installation - 10/23/09 12:37 AM

Install the opposite side in the same manner - here you can see the thrust spacer from the original gear set placed on the new gear hub:
[Linked Image]

Align the cross shaft bore halves:
[Linked Image]

Insert the new cross shaft from the kit, noting proper orientation of the hole for the lock pin - I found it helpful to insert the ice pick to keep good spacing of the cam gears to aid installation of the cross shaft:
[Linked Image]

Drive the lock pin through the cross shaft and seat it as far as it will go - it'll bottom out and you'll feel it when it's seated:
[Linked Image]

Frank
Posted By: FrankR

Re: Aussie Locker Installation - 10/23/09 12:51 AM

Make certain you have access to all four spring slots - adjust the orientation if necessary:
[Linked Image]

Grease and install a pin in each pin bore with the pin step exposed:
[Linked Image]

Grease and install a spring over each pin step and push the spring into the recess as far as it will go:
[Linked Image]

Measure the gap down the center of the locker assembly - it must be between 0.145 and 0.176". Record the number and keep it. If you have a warranty claim, you'll be asked for this measurement. Feeler gauges might work better for this measurement, but mine appears to be near the center of the range at about 0.164":
[Linked Image]

Now set the case assembly aside while you tend to some not-so-fun chores..... more after dinner.

Frank
Posted By: LandRaider

Re: Aussie Locker Installation - 10/23/09 01:05 AM

Thanks for writing this up Frank. Please let us know how it works out.
Posted By: 1986powerram50

Re: Aussie Locker Installation - 10/23/09 01:30 AM

Thanks for the write up Frank. This otta be archived/linked in the important threads thread.

By now the cobwebs otta be almost gone off of the G-Raider <img src="/forums/images/graemlins/cheers.gif" alt="" />
Posted By: FrankR

Re: Aussie Locker Installation - 10/23/09 01:30 AM

Will do, Curtis - and I trust you'll proof-read the text for correct differential terminology. <img src="/forums/images/graemlins/wink.gif" alt="" />

Now for the not-so-fun stuff that you certainly don't want to overlook, or you'll be sorry when your locker eats bolts or chews up a pinion gear......

The ring gear bolt sealant used by the factory is some tough stuff and you have to clean the threads in the ring gear. One pass with the M10x1.25 tap is not enough - it'll take at least 3 passes to get them clean:
[Linked Image]

Now clean the ring gear bolt threads on a wire wheel brush:
[Linked Image]

Spray brake cleaner into the ring gear bolt holes and clean the bolts with it as well....... blow them dry with compressed air..... then clean the ring gear backside and the case flange to make certain there's nothing that will inhibit a good flat clamp so the gear runs straight and true:
[Linked Image]

Place the ring gear on the case flange with the previously made mating marks aligned:
[Linked Image]

Turn the case assembly over and run in 2 or 3 bolts to draw the ring gear tight to the case. Use a liberal amount of RED High Strength Permatex thread locker or equivalent on the bolts and run all bolts in snug:
[Linked Image]

If you don't have a large vise, you can use a WorkMate or any suitable device to torque the fasteners, but make certain you protect the case assembly - torque the bolts to 58-65 lb-ft:
[Linked Image]

Now set the case assembly aside and clean the carrier cover flange before installing the case assembly.

Frank
Posted By: motero

Re: Aussie Locker Installation - 10/23/09 01:35 AM

I can smell the gear lube and grease just from your pictures.
Posted By: fasteddy

Re: Aussie Locker Installation - 10/23/09 01:48 AM

I'm not dead sure, but I call the shaft you call a pinion shaft a side gear shaft.
Posted By: FrankR

Re: Aussie Locker Installation - 10/23/09 01:52 AM

Here's where you might wish that you had removed the carrier - it's time to install the case assembly. You have to lift the case assembly into place while holding the side bearing outer races and adjusting spacers in place on each side. You cannot install the adjusting spacers after installing the case assembly, because there is an interference fit that will require you to install the package as a unit. The installation certainly can be done with the carrier in the vehicle, but it's a very tight fit and the case assembly with races and spacers is awkward to handle. If you struggle with it a bit, you'll eventually figure it out. In the picture below, it's almost snugged up into the rear half of the race bore. I found that once the assembly was started into place, tapping gently with a plastic hammer helped for driving the assembly fully into place - then gentle driving with a drift pin against the spacers (NOT the bearing races!) to seat them helped pull the assembly right up into the half-bore:
[Linked Image]

Now you can install the bearing caps, snug them up a little at a time - alternating top/bottom bolts and sides to "walk" the assembly into place.... so you don't get the cap cocked and bend a race - final torque value is 40-47 lb-ft and here she is - hopefully ready to go climbing:
[Linked Image]

Clean the cover flange and install with black or grey RTV or other oil-resistant sealant. Torque the cover bolts to 11-16 lb-ft. and fill the differential with your favorite gear oil. Aussie Locker folks suggest using whatever the vehicle manufacturer recommends.

This has taken most of a day and I still need to put the front end back together..... but between neighbors interrupting, going to get a haircut and going to the yard for a bit, the whole day wasn't devoted to it...... but then, I also work at a leisurely pace. I'd guess most folks could do the complete job in a full day.

I hope mine is installed correctly - I think it is.... and hopefully this will make it a little easier for others who also haven't installed a locker in the front of a Gen1.

After I build an engine for this beast, I'll report on how the Aussie Locker works - unless someone beats me to it.

Frank <img src="/forums/images/graemlins/cheers.gif" alt="" />
Posted By: FrankR

Re: Aussie Locker Installation - 10/23/09 01:55 AM

Quote
I'm not dead sure, but I call the shaft you call a pinion shaft a side gear shaft.


Eddy, Mitsubishi calls it a "pinion shaft" - maybe because it centers the 2 pinion gears.... Aussie Locker calls it a "cross shaft"..... Damfino what it is, so I just called it what they did.

Frank <img src="/forums/images/graemlins/cheers.gif" alt="" />
Posted By: haztoys

Re: Aussie Locker Installation - 10/23/09 03:19 AM

Looks good Frank .. Nice work ..

You may want to take a punch and "stake over" the hole that the drive in pin goes into on the diff case.. It will keep the pin from coming out ... You would think that the drive pin would not ever come out ..But they have and do ..

David

Hazardous Toys inc
Posted By: Angelo

Re: Aussie Locker Installation - 10/23/09 03:20 AM

Very well written up with plenty of good pics to refer back to. Good job Frank!
Posted By: Mad_Scientist

Re: Aussie Locker Installation - 10/23/09 04:04 AM

Great job Frank. I can imagine how fiddly it was putting the case back in like that. Of course, the Gen2 CAD would complicate things a little on the right side of the diff. I think removing the whole diff in that case would be essential.

Mods, please archive this thread. It will be very, very to many <img src="/forums/images/graemlins/kewl.gif" alt="" />
Posted By: FrankR

Re: Aussie Locker Installation - 10/23/09 04:07 AM

Thanks guys......

David - that's a very good suggestion.

I suppose I didn't think about it because the pin is such a tight fit. Anyway, I don't think I can reach it now that the locker is installed, but if I can, I'll bugger the hole a little.

As tight as the pin-fit is, I don't think it'll back out, but there's nothing wrong with some insurance and it should be noted for others who do this.

Frank <img src="/forums/images/graemlins/cheers.gif" alt="" />
Posted By: icysyrup

Re: Aussie Locker Installation - 10/23/09 04:16 AM

Good write up. I love having mine in and using it. It TOTALLY changes how you drive, and makes life much easier. I followed same procedure and took me uninterrupted a half day total. I had a buddy helping me a little so that sped it up a bit. This def needs to be archived cause others will be getting Aussie's as well I am sure.
Posted By: ryany

Re: Aussie Locker Installation - 10/23/09 05:54 AM

This is much better than the semi-generic instructions that came with the locker. I'm looking forward to digging in & installing the one that's sitting on my workbench waiting for a spare weekend.
Posted By: cmonty72

Re: Aussie Locker Installation - 10/23/09 07:19 PM

Nice job Frank <img src="/forums/images/graemlins/kewl.gif" alt="" />
Posted By: Kevin C

Re: Aussie Locker Installation - 10/23/09 07:33 PM

Great job, very well done photos too.

Kevin
Posted By: Alex Kogan

Re: Aussie Locker Installation - 10/23/09 11:03 PM

Excellent. Should be stickied
Posted By: FrankR

Re: Aussie Locker Installation - 10/25/09 08:34 PM

While reinstalling the axles, I found a minor issue -

You should check your axle end play and re-shim to 0.008-0.020". I replaced the passenger side shim with one 0.010" thicker to get 0.012" end play:
[Linked Image]

Frank
Posted By: 87Montero

Re: Aussie Locker Installation - 10/26/09 02:09 AM

Nice job frank!.. Is that some rust I see on your truck??
Posted By: K_Raider

Re: Aussie Locker Installation - 10/26/09 04:39 AM

Did your last post change Frank? What happened to the axle problem you were having? Yeah, I log onto here waaaayy to much. <img src="/forums/images/graemlins/lol.gif" alt="" />
Posted By: FrankR

Re: Aussie Locker Installation - 10/26/09 09:53 AM

Brendan - yes, the spiders did it. <img src="/forums/images/graemlins/lol.gif" alt="" />

JAgnew8 - yes, I was having trouble installing the driver side axle and thought the problem was a lack of a chamfer in the axle gear to collapse the circlip. So I removed the case assembly and checked the fit on the bench, saw that there is indeed a chamfer cut into the axle gears.... and found that the problem was my installation method. The fit is tighter than the OE gears and requires the outer axle end to be used as a driver...... a little trickier than the original. I was fussing at Aussie Locker unfairly, so I removed the post.

Frank
Posted By: haztoys

Re: Aussie Locker Installation - 10/26/09 02:52 PM

You really should say something about it ... Half the new lockers or lsd's I install ..If its got a clip ..Theres going to be a fight getting the axle in .. I've been greasing the clip to keep it in the middle of the axle for install that helps .. Allways look at a Lock-Right the chamfer can be off ...

Have a good day

David

Hazardous Toys inc
Posted By: FrankR

Re: Aussie Locker Installation - 10/27/09 12:26 AM

David -

After fooling with the axle for quite a while, I installed another circlip and had the same problem, so I took a look at the circlip under a magnifying glass and found marks that seemed to suggest that either there was no axle gear chamfer, or that the circlip wasn't centered:
[Linked Image]

I first re-greased the circlip and centered it in the shaft groove, carefully inserted the axle and tried again - no joy, so I pulled the case assembly, took a closer look and found the axle gears are indeed chamfered. Then, I tried installing the axle into the gear on the bench - no problem...... it went in easily so long as the angle was dead straight and if I used the outer axle end as a slide hammer:
[Linked Image]

And..... it came out easily with a good jerk - just like it should.

I never had this problem with the open OE differential - I suppose because the clearance is tighter with the Aussie gears. The issue is compounded by my Bilstein shocks which have a large diameter and make it difficult to get the right angle on the axle shaft for insertion. I'll have time to try it again on Thursday (my next day off) and I'll remove the shock. I'll bet it'll go in easily once the shock is out of the way so I can see the angle and get a better/straighter push on it.

I wasn't too thrilled about removing the case assembly again, but I found it much easier/faster to do the second time and used the opportunity to stake over the cross shaft lock pin hole, so all was not lost. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Frank <img src="/forums/images/graemlins/cheers.gif" alt="" />
Posted By: Kevin C

Re: Aussie Locker Installation - 10/27/09 01:09 AM

Looking at the photos I see a differance in the taper used to compress the snap ring between the OEM gear and the piece you are replacing it with.

From what I can see in the photos the factory part has a much better leading in to compress the snap ring.

Base on that the locker needs a bit more of a hit and possible some molly assembly lube to lower the friction.

Kevin
Posted By: FrankR

Re: Aussie Locker Installation - 10/27/09 01:33 AM

Dang good eye, Kevin..... <img src="/forums/images/graemlins/kewl.gif" alt="" /> I hadn't compared the two, but after reading your comment, I looked at the photos and you're exactly right - there is a considerable difference in the lead-in taper angle..... like maybe 20 difference. That explains it.

Here's a view of the OE axle gear chamfer:
[Linked Image]

And here's the Aussie Locker's axle gear bevel:
[Linked Image]

I don't think I want to go to the expense of re-cutting that chamfer if I can get it to go in easily with the shock off.... and I don't really want to lose any spline length.... but maybe I'll try some ARP lube on it first before I remove the shock. It really doesn't need much of a bump if it's aligned perfectly straight - but the shock does get in the way of seeing the alignment - so perhaps in the end, it'll be less aggravating to remove the shock.

Good catch!

Frank
Posted By: justice

Re: Aussie Locker Installation - 10/27/09 05:28 PM

Maybe they designed it as such to maximize spline engagement with the axle, since it could possibly see a lot more stress because it's locked..
Posted By: FrankR

Re: Aussie Locker Installation - 10/27/09 05:54 PM

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
Posted By: justice

Re: Aussie Locker Installation - 10/27/09 06:33 PM

Agreed.
Posted By: motero

Re: Aussie Locker Installation - 10/27/09 07:28 PM

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?
Posted By: FrankR

Re: Aussie Locker Installation - 10/27/09 08:14 PM

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
Posted By: icysyrup

Re: Aussie Locker Installation - 10/27/09 08:43 PM

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.
Posted By: FrankR

Re: Aussie Locker Installation - 10/27/09 10:19 PM

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
Posted By: icysyrup

Re: Aussie Locker Installation - 10/28/09 06:22 AM

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.
Posted By: haztoys

Re: Aussie Locker Installation - 10/29/09 01:51 AM

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
Posted By: FrankR

Re: Aussie Locker Installation - 10/29/09 08:54 PM

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="" />
Posted By: FrankR

Re: Aussie Locker Installation - 02/22/10 01:33 AM

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
Posted By: Guns_and_Roses

Re: Aussie Locker Installation - 02/22/10 04:22 AM

what was the part number for that locker?

I cant seem to find it anywhere?


Nevermind. I found it!
Posted By: FrankR

Re: Aussie Locker Installation - 05/20/10 09:41 AM

I had a chance to give the front locker a good workout on sand, gravel and smooth concrete yesterday. It works great!

Steering effort is minimal with a stronger center return. I heard no ratcheting sounds, but I could feel the result as a driveline vibration in a fast turn. The tires will chirp on smooth concrete as it ratchets.

While the effort to counter center return is higher than when the front is free-wheeling, it's not too much. My sense is that anyone should be able to engage the locker and both hubs and drive it all day like that on loose stuff with no complaints. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Frank
Posted By: Oyaji_Jon

Re: Aussie Locker Installation - 05/20/10 04:04 PM

Sweet! <img src="/forums/images/graemlins/kewl.gif" alt="" />
Posted By: ryany

Re: Aussie Locker Installation - 05/21/10 06:12 PM

I'm looking forward to installing mine - using this post as a guide. I'm just waiting for my 4.90 rear gears to arrive so I can have a weekend gear-fest.
Posted By: montypower

Re: Aussie Locker Installation - 07/29/10 05:59 AM

Are these still available? If so... Where? Otherwise, is there a Detroit locker available?

Looking for front diff on 95 SR. <img src="/forums/images/graemlins/kewl.gif" alt="" />
Posted By: FrankR

Re: Aussie Locker Installation - 07/29/10 12:20 PM

I don't know if your truck has the same front differential and spline count as the Gen1 V6, but if so, here's where I bought mine:

web page

Frank
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