1. Open box & review contents.
2. My friend Al is removing the tires to get to the axles.
3. Remove pumpkin bolts & drain fluid.
4. Rotating Drive shaft & Spider Gears to get to the center pin shaft bolt (which U need a 12 point socket).
5. Pin & Bolt Out & remove Spider Gears.
6. Push axle in to remove "C" clips & then pull axle out to clear the spider gears.
Al reaching for the "C" clip he dropped.
Spiders removed.
7. 1/2 of the Aussie Locker Greased up.
8. Insert the 1/2 locker into the LEFT side first (ring side).
9. Slide the left axle into the carrier.
10. Locker bushing installed.
11. "C" Clip installed. Note: The "C" clip should be installed B-4 the bushing, we did it back-wards but figured it out after we read the DIRECTIONS. Actually when U install the center part of the locker, the bushing fit's into it & after U install it U can slip in the "C" clip.
12. Repeat step 11. Aussie Locker installed but not complete.
13. Rotate carrier to install center pin & pin bolt.
14. Installing center pin.
15. Install center pin bolt.
16. Locker installed with springs & spring studs. Sorry, I forgot to take a pic.
17. Install tires to operate locker. Spin one tire forward to with tranny in gear until the tire stops, rotate the other tire back-wards or the other way to check to C if the locker will release, do both sides.
18. Locker installed & checking gap with a feeler guage, min 140. Also U have to check two other areas with the guage but as of right now I can't remember. Just READ the DIRECTIONS.
19. Install pumpkin cover & fill w/fluid. We used a Qt. of Lucas gear oil & balanced it out/topped it off with Valoline.
20. Test drive the Jeep in circles, both ways to test locker.
Note: after install the noise was not that bad but after the factory recommended 200 mile break in it should get quieter. Also, Al states (5speed tranny-AX-15) that the Jeep feels like it had more power & when cornering in 3rd gear the Jeep wanted to buck some, I guess he just has to get use to it.
Hope this helps,
RollBar
P.S. I just kind of threw this together but I'll edit the post later.
P.S.S. Did I mention to READ the DIRECTIONS, :sneak: .
2/03/2008:
Note: The locker was giving us problems before & after wheeling in Ocala. After further review synthetic gear lube (Lucas) was used causing the locker to slip/pop on the road while driving straight on the open road. It was happening quite a bit & the concern was braking or snapping the clips on the Dana 35 w/Superior axles, that's how bad it was.
Fix: Replaced the rear fluid w/regular rear end (MFG recommended fluid, non synthetic) and everything is fine. No popping & no more problems. Replaced w/Lucas & regular gear lube & no problems.
2/22/2008:
Poping came back. Aussie mentions (in the paper work) that the center pin may be a little smaller on some differentials. We installed this locker in a D-35 (about a yr ago) & the pin fit but not real tight. It did waller out the carrier because it may have not been machined correctly. We pulled the locker four times (cause Aussie wanted proof) & the tolerances are correct (16-20 thousands on the shims, max). Our side shims are 20. AL even took the Jeep to Jeepers Den (Black YJ) to have it checked per Aussie & the locker was installed correctly. Aussie is going to send a tech from what I hear to check into this & we will probably have to pull it again, fifth time. The Aussie center pin is smaller than the original D-35 pin from what I am told. So, if you are going to install a Aussie, make sure the center pin is not loose in the carrier or U will be replacing the carrier & maybe axles to.
More info to come.
P.S. U can use synthetic gear lube per Aussie.