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| Note:
This installation was done on a differential that was
removed from the vehicle for illustration purposes. It is not
necessary to remove the differential for the locker installation. |
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| 1.
Using either a bent tool (shown) to pull or a pair of needle
nose pliers to push, remove the E-clips that retain the axle
shafts. |
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| 2.
Unbolt the CV shafts from the axle stubs and maneuver them out
of the way. |
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| 3.
Slide the axle shafts out of the housing. |
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| 4.
Remove the four bolts on the bearing caps Remove the bearing
caps and make sure to keep track of the original location and
orientation of the bolts and caps |
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| 5.
Using a pry bar, gently remove the carrier from the differential
case |
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| 6.
Make sure that the bearing outer races stay with the bearings
that they were originally installed with. |
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| 7.
With the carrier on a clean bench top, locate the hole on the
back of the carrier used to access the roll pin that retains
the pinion shaft. |
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| 8.
Using a metal dowel or other suitable tool, tap the roll pin
out the other side of the carrier |
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| 9.
Remove all but 4 of the ring gear bolts |
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| 10.
Loosen the remaining 4 ring gear bolts and turn them until they
are halfway out of the threads. |
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| 11.
Using a hammer tap the heads of the bolts to unseat the ring
gear from the carrier |
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| 12.
once the ring gear is loose, remove the remaining bolts and
remove the ring gear |
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| 13.
rotate the gear set to remove the spider gears. Remove the side
gears and save the thrust washers. Make sure to keep the thrust
washers on the same side that they were removed from as well
as maintaining the same orientation of the faces. |
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| 14.
Grease all of the parts of the Aussie locker before installation. |
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| 15.
Install Aussie locker side gears with the thrust washers from
the stock gears. Install spacers and new pinion shaft (you do
not need to install roll pin at this point). Using a feeler
gage measure the clearance between the pinion gear and spacers.
The clearance should be between .006” and .020”. |
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| 16.
Remove spacers and slip them into the centers of the driver
gears. |
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| 17.
Slide the driver gears into the carrier. You will have to rotate
the gears so that the flats on the sides are up and down. |
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| 18.
Rotate the two driver gears until the pinion shaft cut-outs
align with the spring pockets. |
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| 19.
Slide the pins into the pockets in the orientation shown in
the pictures |
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| 20.
After all 4 pins are in the spring pockets, rotate the driver
gears so that the pinion shaft cut-outs are aligned with each
other. |
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| 21.
Slide each pin into the hole in the opposite side driver gear. |
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| 22.
Place a spring over the step on the pin and then using a small
screwdriver, compress it into the spring pocket. Make sure that
the spring is fully seated in the bottom of the pocket. |
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| 23.
Rotate the entire assembly until the pinion shaft cut-out aligns
with the pinion shaft hole in the carrier. |
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| 24.
Insert the pinion shaft in the carrier. Make sure that the hole
in the pinion shaft is oriented so that it will line up with
the hole for the roll pin. |
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| 25.
Using a feeler gage, measure the gap between the driver gears.
The gap should be between .xxx” and .yyy”. |
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| 26.
Tap the roll pin until it is through the pinion shaft |
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| 27.
Slide the ring gear onto the carrier as far as it will go. Take
care to make sure that it is as straight as possible. |
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| 28.
Use a small amount of thread locker and thread all of ring gear
bolts into the ring gear by hand. Using a crisscross pattern,
tighten all of the bolts to the proper torque. Make sure that
you draw the ring gear up evenly around the carrier. |
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| 29.
Place the bearing races onto the bearings and slide the carrier
into the differential case. You may need to tap it into place
with a soft face hammer. Do not force the carrier in. If it
does not want to go in, the races or the carrier is probably
cocked. It needs to be perfectly straight while installing. |
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| 30.
Install bearing caps and bolts using a small amount of thread
locker. Torque the cap bolts to the proper spec. |
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| 31.
Slide the stub shafts into the case. You may need to rotate
them slightly to align the splines. (note: you do not need to
install the E-clips on the axle shafts) |
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| 32.
Bolt the CV shafts to the stub shaft flanges. |
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| 33.
Using the procedure described in the standard set of installation
instructions, test the locker for proper operation. |
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| 34.
Using RTV or a gasket, install the differential cover and fill
with the proper amount of fluid. |
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| 35.
Enjoy |
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