2000 XJ, 4.0, 8.25 rear axle, Dana 30 LP front axle, NP242 transfer case, 4.56 gears AW4 auto trans.

Hi all. I recently installed an Aussie Locker up front in my Dana 30. I installed the locker myself and have installed others in the past. Tolerances were within spec, closer to the tight side of the specified range. The problem I'm having is that the locker frequently binds up while turning. It produces a loud and pretty violent binding/clunking. I believe the locker is perhaps engaging/unloading hard. This is of course while driving in 2WD.

Interestingly, this doesn't occur with the front drive shaft removed. I had my front driveshaft out in order to rebuild it. The centering yoke was worn, so I replaced it and the 3 u-joints in the front driveshaft. The locker was practically invisible while the front drive shaft was removed. I could faintly hear the normal ratcheting, but not once did it bind until I put the front drive shaft back in. Now it's exhibiting the same behavior as before I rebuilt the front driveshaft. I'm thinking it could be possible that the transfer case is for some reason sending some amount of torque to the front drive shaft, even while in 2WD.

Any thoughts or suggestions would be much appreciated.

 

Maybe your transfer case is worn? I have a '88 with a aw4, np242, HP30/c8.25, 4.56 gears on 35s and aussie lockers front and rear. I've never experienced anything bad with the Aussies over the years. If i have to do a super sharp turn like in a dead end or similar i'll hear it click and maybe front end clunk but it's never sounded horrible or made me think it broke.

 

It sounds like the pressure of the driveshaft is making the locker engage. One thing I recommend that the manufacturer doesn't is putting Power Punch gear oil additive in the oil. Makes them work smoother and reduces wear.

 

The drag from the front D/S is what's making it engage...

 

Thanks for the responses guys. Would it be advisable to try swapping or rebuilding my transfer case to solve this? I've been considering swapping in an NP231 anyway.

 

Yes, that would probably solve the problem

 

my lok-rite did that too and i have a 231. not sure if i put in the side washers or not. couldn't remember. it would make a hell of a noise unloading. so i removed it years ago. gonna go with a detroit in the front and an elocker in the rear.

 

I would do the opposite of that, Detroit rear and e locker front.

 

Not sure why it would make a difference if it's in 2 or 4 wheel drive but it's so violent in 4 I don't want to keep it in. What could be the reason for this?

 

Ill jump in the Detroit front wagon. After that doesn't really matter whats in the rear