Aussie Locker Install

[muskrat]

I've been chugging away on my Aussie locker install in the Dana 44. So far, the hardest part of the job has been the installation of the inner seals. What a pain in the @ss. Burned through at least 6 of them to get two installed.

Finally finished that and on to the assembly of the locker into the carrier. Hit another road block checking the tolerances. The Cross Pin is at max wear, and it also shows wear where the spider gears were located.

I installed the axle gears, spacers and the cross pin and I'm not hitting tolerance. It needs to be within .006 to .020. I can get a .005 in one side, tightly, but not the other side. I'm thinking my thrust washers are worn, warped enough to throw this off.

This EB has 300K miles on it, and I don't know the last time anyone was in there replacing parts.

This was a bummer. I really wanted the EB back on all fours today. Can't find thrust washers anywhere local, so looks like I'll have to order them and wait for UPS. Want to wheel it next weekend. Hopefully the parts come in
quick.

While I'm ordering parts, may as well get the new cross shaft also.

Do I need to get new ring\carrier bolts? Some say they cannot be reused.

 

[garberz]

I would would definitely replace the ring gear bolts, since you're in there. It's just ugly inside when they fail.

 

[cs_88]

When I first installed my Aussie I wasn't able to get the proper clearance either. Once I replaced my cross pin and thrust washers I was able to get .006".

 

[admin]

I installed the axle gears, spacers and the cross pin and I'm not hitting tolerance. It needs to be within .006 to .020. I can get a .005 in one side, tightly, but not the other side. I'm thinking my thrust washers are worn, warped enough to throw this off.

I had the exact same problem. My thrust washers were warped and I couldn't get the tolerances to match specs. I found new thrust washers locally at a Ford dealership. No parts stores had them. Call a few dealerships if you haven't already.

Also, if you haven't already seen my tech article on installing an Aussie Locker here it is: http://classicbroncos.com/tech/aussie-locker

The inner seals are a pain. The trick is putting even pressure on them so they go in straight. One way is to slide a long pipe down the opposite axle housing and press it against a socket or spacer slightly smaller in diameter than the axle seal. It helps to have a second person at the diff opening keeping everything straight while you lightly tap in the long pipe. Check this out this video at about 2:45 into it: https://www.youtube.com/watch?v=JvxKZbQArnQ

Or you can splurge like I did and get an install tool. It's been years, but I think I got it from Mike at Complete Offroad. They're pricey, but it did the job in one shot; no wasted seals. http://completeoffroad.com/i-122839-inner-axle-side-seal-installation-tool-yt-sa-01.html

But you got yours installed already, so it's all good.

 

[muskrat]

Jon and Garberz, I've read and reread both of ur posts. Great suggestion on the all tread n washers. That's how I finally got them in. Jon, great write up. Printed it out n read it side by side the Aussie instructions.

Just hope it's not the carrier n the pin n washers work. Didn't really c any noticeable warp on washers.

Thanks guys.

 

[garberz]

I saw the allthread trick here, it worked great for me. I can't take credit for it, glad it worked out for you.

Mark

 

[admin]

What's the allthread trick? I searched through your past threads Mark and didn't find it.

Do you run a piece of all-thread through one axle tube with big washers at both ends? Then cinch it down to pull the seals into place?

 

[cs_88]

Didn't really c any noticeable warp on washers.

I didn't notice any warping on mine either.

Might need to change your personal text now.

 

[muskrat]

Yes I do to reflect the the locker n the recent disk / power brake upgrade.

 

[garberz]

What's the allthread trick? I searched through your past threads Mark and didn't find it.

Do you run a piece of all-thread through one axle tube with big washers at both ends? Then cinch it down to pull the seals into place?

Jon, I used a piece of 3/4' all thread about 10' long, a nut and washer against each seal. I got each seal started with the tap of a small hammer. Place the all thread in and slowly spread the washers apart, using the nuts. You're pressing one seal in, against the other. It worked great!. Sorry no pics.

Mark

 

[muskrat]

BTW, I think we are part of a very small community of Aussie Locker users in the EB world.

 

[garberz]

BTW, I think we are part of a very small community of Aussie Locker users in the EB world.

I run 35" tires, my trail buddy runs 37". We haven't been able to destroy one yet. We run rocks, desert, and sand. They behave just like a Detroit, I have no plans on upgrading. I'm not sure that anything else would be an upgrade.

Mark

 

[admin]

Jon, I used a piece of 3/4' all thread about 10' long, a nut and washer against each seal. I got each seal started with the tap of a small hammer. Place the all thread in and slowly spread the washers apart, using the nuts. You're pressing one seal in, against the other. It worked great!. Sorry no pics.

Mark

Got it. Sounds like the tool, only a lot cheaper!

I knew I had some pics from my install. Here's the tool in action:

 

[AussieLocker]

Hi folks, this is Cora from Aussie Locker. We aren't too active on the forums, but just wanted to chime in.

To confirm, I would suggest replacing the cross pin and thrust washers. After that your locker should be within spec, if not give us a call.

Thanks for the support and the well put together install write up!! http://classicbroncos.com/tech/aussie-locker

I would love to see some trail pics and hear stories!

 

[muskrat]

Hi folks, this is Cora from Aussie Locker. We aren't too active on the forums, but just wanted to chime in.

To confirm, I would suggest replacing the cross pin and thrust washers. After that your locker should be within spec, if not give us a call.

Thanks for the support and the well put together install write up!! http://classicbroncos.com/tech/aussie-locker

I would love to see some trail pics and hear stories!

Cora, welcome to the Classic Broncos Forum. Great Forum and a great bunch of helpful EB owners.

I can't wait to try the new Aussie Locker. I hope to finish my install this week. It would have been finished, but I need to source the cross pin and washers.

Hope to be wheeling it on Sunday. I'll post up some picks.

Dave

 

[muskrat]

Received my parts from Randy's yesterday and back on the job last night. Had a little clearance issue with the one half of the locker going into the carrier. I've read that it is rare, but sometimes happens. Just shaved a bit of materials off the top of the part, and in it went.

Just need to get the calibers back on the rotors, find a helper to do the test, then pop on the cover, filler up and go!

Picked up a sweet HD diff cover from my buddy Pete. Thanks Pete. That's all painted up and ready to go.

Fingers crossed the spin test goes well and I'm wheeling her on Sunday.

 

[muskrat]

Locker install is done! Passed the click test on jack stands. Went for a ride and all is good. Locked the front hubs and took a slow corner and heard the clicking.

I'm ready to wheel her on Sunday at Rausch Creek.

Can't wait.

Thanks for the help guys.

 

[astark]

Just wondering how much of what kind of gear oil you used %)

 

[thirdtime]

Been following this thread so I thought I would share my experiences. I installed mine a few years ago, beat on it relentlessly, and it still working great. During the install, I had to grind on the carrier a little to get everything installed, but it was minimal. Jon's write up was spot on, much better than the factory directions. Wheeled with the Jeep guys one weekend, broke a hub, the other axle kept on digging and got me through. Much better than my open front end. Took my first shot at a gear swap recently so I changed to an Auburn due to the carrier difference (Had the Auburn on the shelf, 4 series), I hope it performs as well as the Aussie.

 

[garberz]

Just wondering how much of what kind of gear oil you used %)

I use Lucas 85w-140 gear oil, It takes just under 2 qts.

Mark

Been following this thread so I thought I would share my experiences. I installed mine a few years ago, beat on it relentlessly, and it still working great. During the install, I had to grind on the carrier a little to get everything installed, but it was minimal. Jon's write up was spot on, much better than the factory directions. Wheeled with the Jeep guys one weekend, broke a hub, the other axle kept on digging and got me through. Much better than my open front end. Took my first shot at a gear swap recently so I changed to an Auburn due to the carrier difference (Had the Auburn on the shelf, 4 series), I hope it performs as well as the Aussie.

You can still use the Aussie, they aren't carrier specific. The 3 and 4 series carrier use the same locker. Now you have a spare. Breaking a hub is about the only way to damage one of these lockers. Transferring all the load to one side usually ends up in a failure. The four dowel pins can't take that kind of load.

Mark