[Rollbar]

The Aussie Locker was installed on a '87 yJ with a Dana 35 & Superior one piece axles.

1. Open box & review contents.






2. My friend Al is removing the tires to get to the axles.






3. Remove pumpkin bolts & drain fluid.




4. Rotating Drive shaft & Spider Gears to get to the center pin shaft bolt (which U need a 12 point socket).






5. Pin & Bolt Out & remove Spider Gears.


6. Push axle in to remove "C" clips & then pull axle out to clear the spider gears.


Al reaching for the "C" clip he dropped.


Spiders removed.


7. 1/2 of the Aussie Locker Greased up.




8. Insert the 1/2 locker into the LEFT side first (ring side).




9. Slide the left axle into the carrier.


10. Locker bushing installed.


11. "C" Clip installed. Note: The "C" clip should be installed B-4 the bushing, we did it back-wards but figured it out after we read the DIRECTIONS. Actually when U install the center part of the locker, the bushing fit's into it & after U install it U can slip in the "C" clip.


12. Repeat step 11. Aussie Locker installed but not complete.


13. Rotate carrier to install center pin & pin bolt.


14. Installing center pin.


15. Install center pin bolt.


16. Locker installed with springs & spring studs. Sorry, I forgot to take a pic.


17. Install tires to operate locker. Spin one tire forward to with tranny in gear until the tire stops, rotate the other tire back-wards or the other way to check to C if the locker will release, do both sides.


18. Locker installed & checking gap with a feeler guage, min 140. Also U have to check two other areas with the guage but as of right now I can't remember. Just READ the DIRECTIONS.


19. Install pumpkin cover & fill w/fluid. We used a Qt. of Lucas gear oil & balanced it out/topped it off with Valoline.


20. Test drive the Jeep in circles, both ways to test locker.

Note: after install the noise was not that bad but after the factory recommended 200 mile break in it should get quieter. Also, Al states (5speed tranny-AX-15) that the Jeep feels like it had more power & when cornering in 3rd gear the Jeep wanted to buck some, I guess he just has to get use to it.

Hope this helps,
RollBar

P.S. I just kind of threw this together but I'll edit the post later.

P.S.S. Did I mention to READ the DIRECTIONS, :sneak: .


2/03/2008:
Note: The locker was giving us problems before & after wheeling in Ocala. After further review synthetic gear lube (Lucas) was used causing the locker to slip/pop on the road while driving straight on the open road. It was happening quite a bit & the concern was braking or snapping the clips on the Dana 35 w/Superior axles, that's how bad it was.

Fix: Replaced the rear fluid w/regular rear end (MFG recommended fluid, non synthetic) and everything is fine. No popping & no more problems. Replaced w/Lucas & regular gear lube & no problems.

[Wildbill]

Great write up and pics..... I agree with your end notes. First drive I noticed that when I shifted 1st to 2nd the Jeep pulled to the left just a little. I atributed this to the equal paower going to both wheels. The noise does quiet down, I don't really hear mine at all. Mine still bucks sometimes taking a corner and having to accelerate........try to coast through the corners

Rollbar, you didn't have to do any trimming of the carrier? I had to like the directions stated. I also removed the carrier to do the install on the bench.

Wildbill

[Rollbar]

No we did it right with out the directions, :sneak: . No really, we did not have to to trim the carrier or remove it.

We thought we had to but we figured out an easier way to install it it took some time but slipped right in.

[LostJ]

Nice writeup

I didnt get a new cross-shaft with mine and i had to take my carrier out(d30) :tdown:
hopefully i don't need to take the carrier out when I put one in the d44.

[JeepNWilly]

Nice writeup.

Rollbar would this type of locker be recommended for a daily driver?

[Rollbar]

JeepNWilly, on Aug 30 2007, 10:09 PM, said:

Rollbar would this type of locker be recommended for a daily driver?

Yes, & make sure u get their cross shaft to keep the warranty on it.

[MrSig]

Rollbar that was cool! I wish we would of taken photos last night when tranydoctor put in my River Raider Snorkel..

[Jim B]

Rollbar,

Nice write up. Next time take your lighter so that the inside of the carrier does not come out so dark in the pics.

I noticed this is an automatic locker and more and more people seem to be using it since it first came out. Even though it has the Superior axles, has anyone heard of any issues with the D35 busting axles when getting on it on the trail I guess is has to do with type of terrain.

[JeepNWilly]

Jim B, on Aug 31 2007, 07:54 AM, said:

Rollbar,

Nice write up. Next time take your lighter so that the inside of the carrier does not come out so dark in the pics.

I noticed this is an automatic locker and more and more people seem to be using it since it first came out. Even though it has the Superior axles, has anyone heard of any issues with the D35 busting axles when getting on it on the trail I guess is has to do with type of terrain.

That would be a good thing for me to find out before getting one as I have a D35

[Rollbar]

Willy, IMO, just do both cause in the long run U will anyway.

[TufrThNails]

Great write up. I am thinking you guys made this look like the guys on the car overhaul shows. So easy till you actually try to do it then you realize it is going to really piss you off.

[Rollbar]

Here are some links I found on another topic on JT, very handy.

http://www.offroadlo...1d0f/4e25/.html

http://www.jeepforum...ad.php?t=115029

http://mrpistol.tripod.com/id58.html

http://home.off-road...cks/locker.html

[Rollbar]

Note: The locker was giving us problems before & after wheeling in Ocala. After further review synthetic gear lube (Lucas) was used causing the locker to slip/pop on the road while driving straight on the open road. It was happening quite a bit & the concern was braking or snapping the clips on the Dana 35 w/Superior axles, that's how bad it was.

Fix: Replaced the rear fluid w/regular rear end (MFG recommended fluid, non synthetic) and everything is fine. No popping & no more problems.

[SodMan]

I need to get one of these for the front D30 on my Cj7. that way I can throw the ARB locker in the trash can where it belongs I like the Detroit locker in the rear.

[Rollbar]

Poping came back. Aussie mentions (in the paper work) that the center pin may be a little smaller on some differentials. We installed this locker in a D-35 (about a yr ago) & the pin fit but not real tight. It did waller out the carrier because it may have not been machined correctly. We pulled the locker four times (cause Aussie wanted proof) & the tolerances are correct (16-20 thousands on the shims, max). Our side shims are 20. AL even took the Jeep to Jeepers Den (Black YJ) to have it checked per Aussie & the locker was installed correctly. Aussie is going to send a tech from what I hear to check into this & we will probably have to pull it again, fifth time. The Aussie center pin is smaller than the original D-35 pin from what I am told. So, if you are going to install a Aussie, make sure the center pin is not loose in the carrier or U will be replacing the carrier & maybe axles to.

More info to come.

P.S. U can use synthetic gear lube per Aussie.

[CaptainCody]

Rollbar, on Feb 22 2008, 07:45 PM, said:

Aussie mentions (in the paper work) that the center pin may be a little smaller on some differentials. We installed this locker in a D-35 (about a yr ago) & the pin fit but not real tight. It did waller out the carrier because it may have not been machined correctly. We pulled the locker four times (cause Aussie wanted proof) & the tolerances are correct (16-20 thousands on the shims, max). Our side shims are 20. AL even took the Jeep to Jeepers Den (Black YJ) to have it checked per Aussie & the locker was installed correctly. Aussie is going to send a tech from what I hear to check into this & we will probably have to pull it again, fifth time. The Aussie center pin is smaller than the original D-35 pin from what I am told. So, if you are going to install a Aussie, make sure the center pin is not loose in the carrier or U will be replacing the carrier & maybe axles to.

More info to come.

P.S. U can use synthetic gear lube per Aussie.

So does it still pop all the time, is that what the end result was, I'm confused

[Rollbar]

Yes, it does pop while drive straight like it use to. Installed anew locker per Aussie. The end result is the center diff pin being to small & wore a egg shaped hole in the carrier. The Aussie rep is coming out but U know how that will go. AL took pics so I can't post any right now.

[CaptainCody]

Rollbar, on Feb 22 2008, 10:13 PM, said:

Yes, it does pop while drive straight like it use to. Installed anew locker per Aussie. The end result is the center diff pin being to small & wore a egg shaped hole in the carrier. The Aussie rep is coming out but U know how that will go. AL took pics so I can't post any right now.

But, didn't the pin come from them ? I had one of these type lockers for awhile, POS.!!MIne did the same stuff, I had it in and out like 3 or 4 times too.Never could find anything wrong with it..Finally just put an OX in and now I'm DONE..
On the plus side, I can do one of the installs now with my eyes closed..

[Rollbar]

Yes, the pin came from Aussie.

[CaptainCody]

Rollbar, on Feb 22 2008, 11:30 PM, said:

Yes, the pin came from Aussie.

O.K. so I don't get it... Are they saying that the hole in the carrier is the problem ? I'm just curious, because I got NOWHERE with Detroit with mine..:thumdown:

BTW, really good write up and excellent picture illustrations..

[Jim B]

Rollbar, on Feb 22 2008, 07:45 PM, said:

More info to come.

P.S. U can use synthetic gear lube per Aussie.

This does not sound too good. Keep us updated.

I would still not run synthetic. If this locker can run the regular stuff there is really no reason too especially in Fl in where you are changing fluids as fast as you change underwear. I tried it once and my pig still remained as hot as with the regular. I do run 70-140 per the specks on my axle.

[Rollbar]

CaptainCody, on Feb 23 2008, 01:38 AM, said:

Are they saying that the hole in the carrier is the problem ?

No, the hole in the carrier is not the problem as these aftermarket vendors/MFG R supposed to match/machine their product to match the factory carrier hole.

The Aussie locker center pin on some carriers will not fit the factory carrier hole per my conversation w/AL & his conversation w/Jeepers Den in Orlando. The problem is the locker MFG & not the carrier.

[Outlaw]

Rollbar, on Feb 23 2008, 09:52 AM, said:

No, the hole in the carrier is not the problem as these aftermarket vendors/MFG R supposed to match/machine their product to match the factory carrier hole.

The Aussie locker center pin on some carriers will not fit the factory carrier hole per my conversation w/AL & his conversation w/Jeepers Den in Orlando. The problem is the locker MFG & not the carrier.

I agree with you... But on the one I installed I found the same problem and reused the factory center pin... Have had no troubles with it... If the center pin is in good condition and you can keep the specs on the locker use it stock pin...
This keeps it from moving in the hole..

[CaptainCody]

let me ask ya this...The pin should be the same size as the holes on the locker as well correct, or do they make them to fit a bunch of different apps? Is it acceptable to have play around the carrier bolt and the locker? Cause that to me is counterintuitive.

[Rollbar]

CaptainCody, on Feb 23 2008, 03:03 PM, said:

let me ask ya this...The pin should be the same size as the holes on the locker as well correct, or do they make them to fit a bunch of different apps? Is it acceptable to have play around the carrier bolt and the locker? Cause that to me is counterintuitive.

U R correct, no play = no loss of carrier in the future. Play = loss of carrier in the future.

In my opinion, a selectable locker is the best way to go besides the spool, easier on the axles/gears for every day use. However, true trac & power trax are good lockers because of who they R made by, a gear company.

[bigH]

Great write-up and pictures. I installed one in my '06 Unlimited D30. My instructions said to use my existing cross pin unless it was worn or soft. It did not include a pin from Aussie. I used Lucas High Performance 85-140 Gear oil as recommended in the instructions. I pulled the carrier as instructed and followed everything to the T. (total of 4 1/2 hours)I've put a little over 1000 miles on mine and have had no issues at all. In fact, it is probably the quietest locker I have heard on or offroad. This sounds like it might just be a D35 issue. If anyone running a late model D30 is having issues please let me know.

[TufrThNails]

I just installed an aussie in my D30 and it is absolutely awesome. It is very quiet only make noise unlocked for the first mile in the morning then I never hear it again Unless I turn my wheels all the way to pull a U-turn. it is fairly quiet locked. I used 80w-90 gear oil. The install was hampered by ring and pinion swap issues but I would estimate that it would be fairly simple to do this in 2 to 3 hours now that I have done it once. I will find out soon enough as Jeepinjimmy will be getting one here in the mail pretty soon.