I picked up an Aussie for a steal over here so finally had a go at fitting it. The install was straightforward except for one problem, I could only just get the second cam gear in place, even using no grease. When fitted, my centre gap was too big at 0.182". The thrust washers were in spec at 0.032".

I got a pair of 0.040" washers made, but knew that I was going to have a major problem fitting the second cam gear.

Using some emery paper placed on a flat surface I hand ground the right hand axle gear inner lip until I had just enough clearance when dry. Got it all fitted, then applied grease using a q-tip. My clearances were now within spec at 0.020" and 0.164".

Checked it ratcheted when still on stands, then took it for a very gentle spin. Negotiated some very tight turns on hills in town, it was fairly noisy but behaved well.

My axle is the Dana 35, fitted with 30" tires and a small lift, and I leave it in full time 4wd all the time.

Rob

 

alright. is this a statement of what you did? since you tinkered with the aussie the company know wont warranty it.

 

Yep, this is what I've done. The lip I reduced is the lip the c-clip sits against, and has no effect on the lockers operation.

The locker was bought 2nd hand but un-used, so no warranty applies I imagine. Don't understand how the locker/diff could be so out of whack.

When cleaning my spider gears to box 'em up I noticed some damage on the teeth, so maybe they didn't have long to last.

I'll pull the locker and inpect it in a few months, and change the wheel bearings at the same time.

Rob

 

weird. our shop and literally installed 200 of these and not a single issue. strange

 

Beats me. It's fitted and in spec now. When I pull it, I'll measure everything and try to see where the problem lay.

Rob

 

glad you got it going!

 

Cheers. So am I.

Rob

 

Synthetic gear oil will quieten it down a little bit.

 

The Aussie is working perfectly, I can report. I negotiated some very tight steep turns in the wet today. I was in 2WD, and previously the Jeep would just spin the inside wheel, but today it locked up and threw me up that hill.

I'll still inspect and adjust shims late summer though.

A thought occurred to me, maybe the original owner of the locker sold it because he couldn't get it to fit.

Rob