I forgot to ad in my post above. My tolerance between the cam gears was at the tight end of the allowable.

 

Did you try using a smaller thickness thrust washer to open it up a little?

 

I will say this, Aussie does have great customer support. My front D30 with Aussie is several years old and I have had Zero issues. The rear C8.25 IMO just has to much stress on it to last. If you are climbing hills the whole weight of the vehicle is on that rear axle.... I got a full refund and went with a Detroit in the rear. Aussie is still a great product and they stand behind their stuff....

 

anyone have a part number on a hardened cross pin? I have to take my 8.25 apart with my aussie locker in and I mine as well put in a new pin... mine did look a bit scored

 

This is what I put in with my Aussie the second time around:
YGASLXP-C8.25 Chrysler 8.25'' Spartan Locker cross pin shaft $25.07

No problems so far - just a DD for the most part but about 10k miles.

Hope it helps.

 

If it does this and you are accelerating truly in a straight line something is wrong other than the axle.
Think about it, if you are moving straight, both wheels have to be traveling the same speed. It would be physically impossible for the side gears of the locker to disengage and move seporately.
Unless something is making them turn a different speed. I.E. tire diameter, axle tube (which would have nothing to do with the locker lining up in the carrier.) Even the vehicle being square. If you have a bad control arm bushing on one side and the front axle isn't straight, causing the rear to track the same.
Mine used to do it too, but on very slight corners, especially at steady speed with not a lot of load. It's the nature of tje beast.
But if your really driving straight, something else is wrong.
Measure center to.center of tje wheel hub front to back on each side and make sure the axles are square.

 

Although it could be the vehicle, as flat and straight as a road may seem, it's not perfectly flat or perfectly straight. With the locker engaged under acceleration the axle shafts are like big torsion springs and if there is enough variation in the road while under enough power to keep the locker locked a lot of energy can build up.

I had my Aussie for almost a year (maybe 10k miles or so with no off-roading, totally stock) and it began doing the exact same thing. Under moderate/heavy acceleration getting on the expressway in a relatively straight line it would let loose with a bang and the vehicle would buck to one side. Even driving down the road 70 MPH, at times it would do the same thing.

After sending it back for evaluation, it was replaced under warranty. As with the first locker, new spacers and cross-shaft were installed. With the first locker, I used a new cross-shaft from the dealer, with the second locker the new cross-shaft was an after-market hardened one (listed in post above). Almost 10k miles on the second locker and no problems so far.

My Son checked the replacement dealer pin (from the failed locker) and I think it was about RC56 and the 'hardened' one was about RC60 - both fairly hard.

Just my 2c.