ohio95xj

okay, so here's the deal, i've had an aussie locker in my dana 30 for a year. any time i crawl up a large obstacle, as soon as i give it gas with one of the front tires against it, it makes a loud "crack" noise, it sounds aweful, but it locks right up as it's supposed to, it also does it if one of my front tires drops off a decent size ledge before the other one. it has always done this, but it doesn't seem to be skipping or anything, and or doing it easier. i'm trying my best to describe it.

schirm

Are sure it's the locker? Could it be your ring gear deflecting from some bolts loosening up? Cracked carrier? It's been doing this since install I assume? Idk, I think I'd crack the pumpkin open and take a look to make sure all bolts are tightened and look for flaws

xjzaped

The Lock Right in the back of my old F150 used to randomly do something similar. I thought it was snapping shafts or something and would always check but never had any damage. It may have just been how I used to drive it and it could've just been a hard engagement from a quick differentiation session. If my XJ's Aussie does it...I've never paid any attention to it.

ohio95xj

I don't have the thing to measure the gap of the aussie locker, does anybody know any way to check it

ohio95xj

okay, so i took the cover off, everything is tight, no sheared bolts or anything. but i did notice that the aussie was not within spec. it is, about 3/8 and the cut off is like 2.8/8 i totally forgot to check, there does not appear to be any damage to the locker, springs and pins are both in good shape. so my next question is. i am going to big rock orv park tomorrow, i should be okay to wheel, considering i have been for a year with no problems(minus the noise)
i would get new thrush washers, but i don't see the point since i will be getting a whole new carrier when i regear in 2 months(stupid carrier break)

schirm

Hmm, interesting that your only symptom is noise but I don't know if wheeling while your locker is out of spec is a good idea. Thrust washers are cheap and you might even use the new ones with your new carrier.

98XJ40K

If you have a lowes or Home Depot near you, they have feeler gauges for $5-10 IIRC. that's where I got mine for my Aussie install.

ohio95xj

i wheeled the **** out of it all weekend, the noise persisted, but again, no other symptoms.

Bossokee

If the gap is that wide maybe you could try shimming the outer couplings about 50 thousandths each to close it up? You can use a caliper to measure it accurately and figure out how much shimming you need.

schirm

Wow! Pretty impressive that you don't have any other symptoms.

schirm

I'm curious OP. How loud is the popping? Scary loud or just a little louder then it should sound?