Torq-Masters Aussie Locker series User manual

INSTALLATION MANUAL
INTRODUCTION
Your new Torq-Masters “Aussie Locker®” will provide you with the maximum in advanced traction per-
formance available. The Aussie Locker is an Automatic Precision Locking D fferential—it does not require a
switch or external electr c or air control lines to activate nor does it contain frictio clutch packs. When-
ever terrain onditions would normally cause wheel spin to occur, the Auss e Locker automatically trans-
fers up to 100% of the available torque to the wheel with the most traction The result is a dramatic
increase in the performance capabil ties of your vehicle. This is why the Aussie Locker is called the
“Traction To Go Anywhere” advanced traction enhancement system. A 4WD vehicle fitted with one
Aussie Locker will, in general terms, have more than twice its original off-road capability. A 4WD vehicle
with lockers in both front and rear differentials will hav truly amazing traction, enabling it to travel over
seemingly impossible terrain with less effort that ever before
Installation of your new locker is accomplished by removing the differential gears from the differential
case and installing the Aussie Locker omponents in their pla e. This typ of installat on can be made by
the weekend mechanic who is familiar with the operation of a differential and who is able to exercise
appropriate care during the installation process. Normal installation takes about two to three hours when
these instructions are followed. They also assume that the installer has a shop manual covering his
vehicle and that he s familiar with th procedures used in removing wheels, axle shafts, etc Short uts
should not be attempted unless the installer is very familiar with the shop manual procedures for his
vehicle.
Great care has been taken in developing these instructions for the proper installation of the Aussie
Locker; however, the final results are the resp nsibility of the installer. After the l cker is ins alled, the
safe operation of the vehicle is the responsibility of the driver—anyone who drives it should read the
Operator’s Guide for additional information on how to safely operate your new locker-equipped vehicle.
We suggest that you read these instructions before beginning your installation to familiarize yourself with
the steps performed for your particular axle type and to determine what tools you might need
U E OCKAUSSIE LOC
A SSIE LOCKAUS E LOCK
AUSSIE LOCK
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FOR C CL P AND NON-C-CLIP AXLES
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A S E KSS E C E
AUSS E LOCKERAUSSIE LOCKER
AUSSIE LOCKER
INSTALLATION INSTRUCTIONS FOR SPICER (DANA) MODELS, AMC-
You new r Mas er “Auss e L ker®” w ll provi e ou w th he max mu in a a ced tract
formance available. he Aussie ocker i an Automat c Preci i n Loc ing iff rential—it d es not
swi ch or exte na el ctric or a r con rol lin s to ac ivate or does it contain fr ction clutch pack
ever t rrai c nd t ons would norm lly ause heel s in to o c r the ssi Lock r au omatical
er up to 100% of he avail ble t que o he w eel wi h th most trac on. Th resu t i a d
i r ase i he pe or ance apabili s of your veh le Th i why the Au s e Locker s ca
Tractio o Go Anywhere adv nced tract on e hanceme s stem. A 4WD veh cle itted w
Aussie Locker wi l, in gen ral terms, have more tha twice its original f road capability A 4WD
w h lockers n bot ro t and rear d ffer n ial wi l ha
Instal atio of your new loc er is accomp ished y remov n the di ferential gears from the dif
case and stal n t e Aussie ocke ompone s n the r p ace. h s t e f n talla ion can be
the wee en mechanic wh s familia with he operat on of a differen ial and wh is able o
appropr a e care d r n he in al a ion process. ormal nstal atio t kes ut tw to hree u
these ins ruc ions ar foll we . They als ass me tha the insta l r ha a sh m nual cove
ve icl and tha e s fami i r with the rocedures u ed n removing wheels axle shafts et S
Grea care has b en tak n n d velopin the e nst uctions or th proper nstallation o th
ocke howe er he fi al resu ts are he re pons b l t f the n taller. Afte t e lock r is i sta
a e ope at on of he e icle is the r spo i ilit o the dri er—anyone wh drives it sh uld
e s es ha you read hese inst ct ons b fore be nnin your inst l at t familia

STANDARD DIFFERENTIAL OPERATION
The standard, or “open” differential provides two functions:
1. Transmits engine power via the drive train to the wheels to move the vehicle; and
2. Allows differential action between the two wheels–permits them to rotate at different speeds
during cornering to eliminate drive train damage and tire scuffing.
The standard differential design always provides equal amounts of power to each wheel Thus, in normal
driving with no tire slippage, half (50%) of the incoming engine power is transmitted to each wheel, or
50-50. In a slippery traction situation, if one wheel spins with only 10% of the engine power applied to it
the other wheel also receives only 10% of the power, or 10-10. This means that the vehicle is trying to
move with only 20% of the total power applied to the ground such that it may not move. The vehicle is
stuck.
Your new Torq-Masters Aussie Locker overcomes the traction deficiencies of the open differential by
providing as much as 100% of the available power to either wheel (100-0) when the other one is on a
slick surface or even off the ground in a hole, yet it also allows the wheels to rotate at different speeds
during a turn This means that if one wheel is on solid ground with excellent traction and one wheel is on
ice and would slip with 10% of the power applied, that the one on solid ground would receive 90% of the
power and the other one would receive 10% (90-10) The 90%-power wheel will move the vehicle just
fine, so you wouldn’t even know that you’d have been stuck.
For you techie types, the reason that this unequal division of power can occur is that the axle shafts act
like torsion bars. Power is applied to both axles; when the 10% wheel (low traction) begins to slip, the
axle shaft for the 90% wheel (good traction) wraps up a little more as engine power is applied. The 10%
wheel slips a little more and the 90% axle wraps up a little more until enough power is finally applied to
move the vehicle It may move before all 90% is applied, but these illustrations show the theoretical
maximums that may come into play. As your vehicle climbs up a hill, this torsion bar effect transfers
power back and forth instantaneously from side to side as one wheel, then the other one, slips a little and
then regains traction. Your new Aussie Locker thus effortlessly and automatically gives you the most
power to the wheel with the most traction, and you just keep right on going. Onward!
PRE-INSTALLATION INFORMATION
The Torq-Masters Aussie Locker is designed to fit into a standard or “open” differential case Limited-slip
or Posi-Traction differentials use clutch packs, such that these differential cases are not compatible with
the Aussie Locker. If you have a limited-slip differential you will need to purchase an equivalent open
differential case, pinion shaft and side gear thrust washers and have the case installed prior to the
installation of the locker Setup of the case includes setting the differential bearing pre-load and the ring-
and-pinion backlash, which generally must be done by a shop having the right knowledge and tools.
As with most factory differentials, the Aussie Locker is designed to be installed with a factory thrust
washer under each axle gear. It is imperative that your thrust washers are not worn, warped, cracked or
scored and that they be of the original thickness. If your washers are worn or damaged, purchase new
ones. They are cheap and are good insurance If you do not install thrust washers of the proper thickness
and in good condition, the contact patterns will show the difference which will void the warranty.
2 Allows if ere t al actio bet ee th wo w eel –perm ts hem o r tate at iffe
d ring ornerin to e iminate drive train amage an re uff n
r v ng with no t re slippage ha f (50%) of he n om n en n ower i t ans itted to each wheel or
50 50. n a lippery trac ion itua i n f n heel sp ns with onl 10% f he engine power pl ed t it
the ot er wheel als e eives only % of the po er o 10 0 h s mea s hat the vehicle is tryin to
move wit nly 20% f he o al p w r ap ie to th ound s h t at it may n mo e The eh le is
stuck
rov ding s much as 1 0% of he av lab e p we to e her w eel (100-0 w e he ot er o e s on a
s ick surf ce or ev n ff the r n in a hol , yet i a a l s the whe s ro a e differe t spee s
d ri a turn Th s means that if one wh el s n sol d ground w e cellent tr tio n o e wh el is on
ice and wo ld s p ith 10% of t e p wer a p e t a the n on ol d gr nd w l receive 90% of he
power nd th ot er e w ld receive 0% 90 0 Th 90%- owe wheel will m ve the ehic e st
fine s you w ldn’ even know tha y u d h ve been stu k
l ke tor on bar Power i appl ed o b th axles when he 10% w ee ow t ac i n) be ins to sl p he
axl shaft f r the 90% wh el (goo t a tion wraps up a l t e more as n ne ower i applied he 0%
whe l sl ps a littl more and he 90% a e w aps p a it e m re unt l enough powe i fina ly li d o
m e t e e cle It m m e before al 90% s p lied b hese i l tra ions how the heore i al
maxim m t at may ome into p a A ur v h c e im s u a hil his t rs o bar effe t transfers
power ba k d orth tan ane sly ro sid to side as ne wh e t he other ne s ps li tle and
then egains tr t o Your new Aus e cker thus e fort essl and aut ma i a l g v s yo he most
p w r to the wheel w h th mo t tra t on and you ust keep ri ht o oing Onw rd!
r Pos Traction d ferent als se c utch a ks s ha these di fe nt al ases are not compatible w h
the Au s e Lo er If y h ve imit d- ip differ tia yo l eed t pur hase an eq iva ent pen
d ff rent a ca e i on aft n s e ear thru t ashers an hav t e ase ins a led prior to the
installation of the o ker Set of t e ca e in es s tting the d ff renti l be ring re-load n t e r -
and-pin o ba lash wh ch generally mus be done by a s op ha ing the righ n wle e an o l
wa her u der ea h a e ear It s e at ve t at you t rus was er are not wo n w rped ra ed or
scored and t a th y be of t e or g al h kness I yo r wa hers are wor o da aged p ha e n w
o es They are heap and re good s ra ce If do n t nstall hru t washe s of the proper th ck ess
and oo cond t on the o tact atterns w l ho he d ffere e i h w l o d he w rra y

AUSSIE LOCKER PARTS
The Aussie Locker kit consists of the following parts:
Two cam gears
Two axle gears
Two spacers
Four pins
Four precision springs
Insta lation Manual
Supplemental Installation Information (if applicable)
Operator’s Guide
Sticker
Additional parts for some models:
USSIE LOCKER P RTS
h i k ki i h ll i
o l g s
o s er
F i
o pr i i i
ll i l
pl m nt l In t ll i i (i li l )
p r t r’ id
tick
i i l l
Cross shaft (pinion shaft)—The Dana 35 models come with a special cross shaft.
Thrust block—Future models may include a thrust block where required.
ax r
s ers
F n
F r c
S ment In t ( )
r r’s G
Sti er
i i
Cross shaft (pinion shaft) The Dana 5 models come with a special cross shaft
Thrust block Future models may include a thrust block where required
ADDITIONAL PARTS USED
You will use your existing side gear thrust washers and cross shaft(s), assuming that they are in excellent
condition. These parts must be replaced if your differential is high-mileage or if wear is evident. If you are
also replacing axle shafts as part of this installation and if your differential has a thrust block, check to see
if it needs to be changed or if end-play adjustment is required.
Note: Thrust Blocks: Toyota Land Cruiser installations do not use the factory thrust block; Jeep AMC-20
differentials do use the thrust block. (If axle shaft end play is involved (AMC-20), the thrust block is required
for correct installation.)
Also note that for all differentials the spider gear thrust washers are NOT used.
Before starting the installation be sure that you have replacement gear oil of the type recommended by
the vehicle manufacturer, and any seals that will need to be replaced. If the vehicle is to be used in hot
weather we recommend the use of 85-140 gear oil, which will provide adequate lubrication and minimize
any sound. Also, synthetics can be used with the Aussie Locker. A dial caliper or a micrometer and set
of feeler gauges are also needed for checking the various existing parts to determine if they
need replacing.
SHOP MANUAL PROCEDURES
As stated above, it is important for you to have your shop manual available and know the R&R proce-
dures that apply to your particular vehicle. The Aussie Locker instructions will describe in detail how to
install your new locker, but they will only mention in general terms about how to remove backing plates
(if even necessary for your vehicle), pull out the axle shafts, remove the differential case, etc. It is up to
the installer to determine the proper method for axle housing and differential disassembly, and be able to
remove the pinion shaft from the differential case so that the locker can be installed.
DIFFERENTIAL DESIGNS
These instructions will assume that the installer has already consulted the shop manual and/or the
internet and various club resources and determined what type of differential design is in his vehicle. There
are two types of axle housing designs in which the Aussie Locker is used. These are: (1) Integral carrier,
such as in the Spicer (Dana) line; and (2) Removable carrier (third member), such as in Toyota Land
Cruisers (although in these vehicles the rear carrier generally is not removed from the vehicle). In turn,
these two types of axles have several differential designs, including: (1) C-Clip axle shaft retention (Ford
8.8, Spicer 35, Land Cruiser with thrust block, etc.); (2) Bearing retainer axle shaft retention (Jeep AMC-
20 with thrust block); (3) Full-floating axles (Land Cruiser fronts, some rears, early Dodges, etc.). The
Aussie Locker design will operate with all these various types of differentials.
Two axle gears
Two spa ers
Fo pins
Four prec
t ll M
Suppleme al nst
Operat r’s Gu de
Stic er
d i
r ss sh ft pini n sh ft Th D n 35 m d ls m ith sp i l r ss sh ft
Thrust bl k Futur m d ls m in lud thrust bl k h r r quir d
ADDITIONAL PARTS USED
You will use your e isting side gear thrust washers and cross shaft(s), assuming that they are in e cellent
condition These parts must be replaced if your differential is high mileage or if wear is e ident If you are
also replacing a le shafts as part of this installation and if your differential has a thrust block, check to see
if it needs to be changed or if end play adjustment is required
Note: Thrust Blocks: Toyota Land ruiser installations do not use the factory thrust block; Jeep AM 0
differentials do use the thrust block (If axle shaft end play is involved (AM 0) the thrust block is required
for correct installation )
Also note that for all differentials the spider gear thrust washers are NOT used
Before starting the installation be sure that you ha e replacement gear oil of the type recommended by
the ehicle manufacturer, and any seals that will need to be replaced If the ehicle is to be used in hot
weather we recommend the use of 85 140 gear oil, which will pro ide adequate lubrication and minimize
any sound Also, synthetics can be used with the Aussie Locker A dial caliper or a micrometer and set
of feeler gauges are also needed for checking the various existing parts to determine if they
need replacing
SHOP MANUAL PROCEDURES
As stated abo e, it is important for you to ha e your shop manual a ailable and know the R&R proce
dures that apply to your particular ehicle The Aussie Locker instructions will describe in detail how to
install your new locker, but they will only mention in general terms about how to remo e backing plates
(if e en necessary for your ehicle), pull out the a le shafts, remo e the differential case, etc It is up to
the installer to determine the proper method for a le housing and differential disassembly, and be able to
remo e the pinion shaft from the differential case so that the locker can be installed
DIFFERENTIAL DESIGNS
These instructions will assume that the installer has already consulted the shop manual and or the
internet and arious club resources and determined what type of differential design is in his ehicle There
are two types of a le housing designs in which the Aussie Locker is used These are (1) Integral carrier,
such as in the picer (Dana) line; and ( ) Remo able carrier (third member), such as in Toyota Land
Cruisers (although in these ehicles the rear carrier generally is not remo ed from the ehicle) In turn,
these two types of a les ha e se eral differential designs, including (1) C Clip a le shaft retention (Ford
8 8, picer 35, Land Cruiser with thrust block, etc ); ( ) Bearing retainer a le shaft retention (Jeep AMC
0 with thrust block); (3) Full floating a les (Land Cruiser fronts, some rears, early Dodges, etc ) The
Aussie Locker design will operate with all these arious types of differentials

PRELIMINARY AXLE DISASSEMBLY STEPS
NOTE: the following steps and paragraphs are suggestions that we provide to help you with the successful
installation of your new Aussie Locker. You are ultimately responsible for the safe installation of your new
locker and the safe operation of your new locker-equipped vehicle.
The following general steps are done prior to removing the rear differential; similar steps are used for the
front unit. They are meant only as a guide to be used in disassembling the axle for your particular vehicle.
Consult your shop manual for the exact steps that are needed.
1. Position the vehicle on level ground and block the front wheels.
2. Loosen the rear lug nuts by 1/2 turn if the tires will need to be removed. Generally, for C-clip axles, the
tires can remain in place.
3. Release the emergency brake and put the transmission and transfer case in neutral.
4. Carefully jack up the rear axle and place it on jack stands.
5. Remove the tires (if needed).
6. Loosen the bolts around the differential cover or the around the third member. Drain the gear oil. Remove
the cover.
7. If you have determined that your vehicle has a C-clip differential, proceed directly to the section below
entitled C-Clip Axles.
8. Observe the ring gear to see if it is thin enough so that you can pull out the pinion shaft. If so, proceed to
the section below entitled Thin Ring Gear.
9. If the ring gear is too thick to be able to pull the pinion shaft out past the teeth, proceed to the section
below entitled Thick Ring Gear.
Notes:
1. The pinion shaft is usually retained by a special bolt or by a roll pin or even by a solid pin. In some
differentials a bearing cap must be removed to enable the bolt or pin to be removed using a small wrench
or a long punch Consult your shop manual for the exact procedure.
2. If you find one thrust washer, there are two (1 per each axle gear). Sometimes they “stick” to the backs
of the side gears or to the case and one seems to be missing. Check very carefully.
REMOVAL OF THE DIFFERENTIAL—C-CLIP AXLES
The following steps are a general guide to removing the differential assembly from C-clip axles. Consult
your shop manual for the detailed steps required to open up the differential housing to expose the
differential. C-clip axles are the easiest design for differential replacement; in these axles the differential
case remains in the vehicle and the installation of your Aussie Locker is done in the vehicle rather than on
the bench. Note that with only one person, removal of the tires makes sliding the axle shafts in and out
easier.
1. Remove the pinon shaft.
2. Remove the thrust block (if present).
3. Push the axle shafts inward and remove the C-clips.
4. Pull each axle shaft out by about three inches.
5. Remove the spider gears and side gears and all thrust washers.
6. Proceed to the section below entitled Examination and Preparation of the Parts.
REMOVAL OF THE DIFFERENTIAL—THIN RING GEAR
If you have determined that the ring gear is thin enough so that the pinion shaft can be removed without
further disassembly, do not remove the differential case from the vehicle. Your new Aussie Locker can be
installed with the differential case remaining in place. If your differential is in a third member with no
removable cover on the axle housing, remove the third member from the vehicle and place it on the
bench. If the ring gear is thin enough, follow instructions 1, 3 and 4 below but do not remove the
differential case from the carrier. (As an example, this describes Land Cruiser front differentials which
have full-floating axles.)
E I I X E DIS SSE BL S E S
i st lla i n f r ne A e c e Y r t mat l on e or th s f ns l tio f r ne
l cke h f p r ti n f o r ock r pp veh cl
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f
ni The r ant l g id t d i di assemblin th a l r o r r i l r hicl
C s lt r sh p n l f r the e ct s that need d
2 Loo n h a ug n s b 1/2 tur t tir s w n ed t be
tires c e i in ce
R le e he m r enc b
4 Caref ll a k up th re r a l ac i n ck d
5 Rem he ti es f d d
Lo en t bol s r nd the
th c er
If y ha
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O erv t ri ge
t s cti b w enti Th i G r
If t ri g g ar i t o thic e ble to
b l ti led i k R n G ar
iff r i s in c m st be r ed to b h b lt r n o be e o sin a m l
or lo g p h C s lt ur p m u l f r h e ac pr ced r
If u nd o e t r t sher ther r t ( e c axl g )
o the e g a s r t he c e nd o e em to e mi s ng Ch c y c ef l
E O O HE DI E E I C C I X ES
ll i l i i i i l l li l l
l h il d t i d h di i l i h
diff e ial C li l r the asi t de i f r di fe en i l re la m t i th e a l s h differe ti l
c e r ai i th hicl d h in t ll tio f r i L k r i d n i the ehicl r t r tha n
the b n h N t th i h nly e ers r v l th ti es a lidi the l h ft i a d
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2 Re o e the thr lo
3 P th x e a ts n r d r m
4 P ll ach ax e aft ut b b th e ch
5 Re ove h s i e ears a d s d ar nd a
Pro eed the s c ion b lo e tit ed x mi at o an Pr a
E O O HE DI E E I HI I G GE
i i i i i i i
f r her di a bl do n t em he diff r ial cas fro th hi l r ne i ke a b
i ll d i h di i l i i i l f di i l i i i d b i h
r mo bl c r n h l h i r o he third b f t i l nd pl c i n he
b h f he ri r is thi en g f ll i s r i 3 d bel b t d ot re the
dif r ti l fr m t arri r (A l this d s rib L n r is f on di er ti ls i h
h f ll fl ati l )

1. Remove the pinion shaft.
2. Pull each axle shaft out by about three inches.
3. Remove the spider gears and side gears and all thrust washers
4. Proceed to the section below entitled Examination and Preparation of the Parts.
REMOVAL OF THE DIFFERENTIAL—THICK RING GEAR
If the ring gear is too thick to be able to pull out the pinion shaft, the differential case must be removed
from the carrier and the ring gear removed from the case This process requires removal of the differen-
tial bearing caps and outer races. In some differentials the differential bearing pre-load and ring and pinion
backlash are set by shims, while in others these values are set by bearing adjusters. Both the pre-load
and backlash must be correct for your differential assembly to operate properly. Assuming that your
differential has already been operating satisfactorily, the following removal steps are a guide to help you
re-install your differential case into the carrier without having to measure and set up these values again.
Be sure to refer to your shop manual for additional information.
INTEGRAL CARRIER
(Carrier is a part of the axle housing—holds the axle tubes, diff case and drive gears)
1. Check your shop manual for the proper procedure for removing the differential case. In the Spi er (Dana)
line f r exampl the shop manual will usually recommend the use of a large tool called a “carrier
spreader;” however, many mechanics will instead remove the case with a pry bar. Consult your club and
nternet sources for the procedure for you to use.
2. Mark the differential bearing caps as to orientation and side with a punch or marker. Remove the bearing
cap bolts and caps
3. Pull out the axl shafts by about six inches
4. Pry out (remove) the case. As the ase is being removed, BE SURE TO NOTE THE LOCATIONS OF THE
DIFFERENTIAL BEARING SHIMS ( ote that in some Da a Sp cer axles the shims are located under the
carrier bearings a d thus can ot be removed or lost unless the bearing is pressed off). It is extremely
mportant to put these shims back in the same location and order during re-assembly.
5. Mark the differential bearing outer races as the case is coming out so that they can be re-installed on the
same sides
6. Mark the ring gear to case location
7. Remo th ring gear from the case
8. Remove the pinion shaft retaining pin/bolt.
9 Remov th pinion shaft
10. Remove the spider gears and side gears and all thrust wa hers
11. Proceed to the section below entitled Examination and Preparation of the Parts.
REMOVABLE CARRIER (THIRD MEMBER)
(Carrier is not a part of the axle housing—holds only the diff case and drive gears)
1. If your particular axle hou ing has a over, and the pinion shaft can be removed without removing the ring
gear (such as in Land Cruis r rear C-clip axles), do not remove the third member but refer to “C-clip Axles”
or to “Thin Ring Gear” above (depending on your particular design) Otherwi e, remove the third member
from the vehicle and place it on the bench (See the shop manual for the steps required, which will include
pulling the axle shafts out a few inches, disconnecting the drive shaft, draining the gear oil and unbolting
the carrier.)
NOTE: If your third me ber h s been taken out of the vehicle but has a thin ring gear such that the pinion
shaft can be removed (many Land Cruiser front axles, for example), DO NOT remove the case from the carrier,
but proceed to step 9 below.
2. Mark the differential bearing caps as t orientation and side with a punch or marker Also, and this is
extremely important, mark the left or right side and rotational position of the bearing adjusters so that
they can be re-installed in exactly the same way.
1 em h pini sh ft
ull h a le shaft ut y b ut th in h s
3 m e th spid e d s d r n ll hru t sh rs
4 Pr d t th s ti n b l ntitl d E min ti n nd Pr p r ti n f th P rts
REMOVAL OF THE DIFFERENTIAL THICK RING GEAR
If the ing ear is to thick to be abl t pull out e ini n shaft the differential se must be rem ed
f om the arrier and the rin ear rem ed fr m the ase This process equires rem al f the diffe en
ial bearing caps and u er races In s me differentia s the differential bearing pre l ad and ring and pini
back ash are set b shims hile in thers hese alues a e se b bearing adjusters Both the pre l ad
and ba klash must be orrect for ur iffe ential asse bl t perate pr perl ssum ng that our
differential has alread been op r ting s tisfa tor l he foll win emo al steps ar a guide to help ou
e instal ur differential ase int the carr er without ha ing t measure and set up these alues again
Be sure to refer to our shop manual for additional information
INTEGRAL CARRIER
( arrier is a part of the axle housing holds the axle tubes diff case and dri e gears)
1 he k y ur h p manu l f th r r pr du e f r m i g h diff nti l se I th Spi r (D n )
lin f mpl th sh p manual ill su ll r m d h us f l rg t l ll d rri
pr ad r; h e er many me h ni l in t ad r m th s ith pr b r nsult ur lub nd
nt n s ur th r d r f u t se
2 k h fer ti l b ring ps s t ri nt ti n nd sid ith pun h r m rk r R m th b ring
p b ts nd aps
3 P ll ut the sh fts by b t si in h
4 ry ut (r m ) h s As th as is b n r d BE SURE T N TE HE L ATI NS F THE
FFEREN I BE R NG SH MS ( t h in s m D Sp a l s h shi s a l ted u d th
a ie b in d thu an t b r m ed l t nl s h b ar ng s pr s ed ff) It is tr m l
m rta t t put h se hims ba k in h s m l at n nd rd u n r ssembly
5 Ma k the diff r nti l b ring ut r r s s th s is ming ut s th t th n b r inst ll d n th
id s
6 M rk t ng ge t s l ati
R m th in g r fr m th ase
R m th pini n sh ft r t ining pin b lt
9 R m th pi s ft
10 m e th spid e r d s d r nd ll t r st rs
11 Pr d t th s ti n b l ntitl d E min ti n nd Pr p r ti n f th P rts
REMOVABLE CARRIER (THIRD MEMBER)
( arrier is not a part of the axle housing holds onl the diff case and dri e gears)
1 If ur p rti ular le h u g has n the p i n shaft n b m d ith ut m ing th ri g
a (su h s n Land s r l le ) d t m t thi d m b but f t lip l s
r t Thin Ri g Ge b ( p ndi g n y u ti l r d ign). th i r th th d memb r
m h hi l an pl it t e b n h (S the h m nu l f r th s eps qu d h h ill in l d
llin th l sh fts ut f in h s dis nn ting th dri sh ft dr ining th g r il nd unb lting
th rri r )
N TE f y ur thi d m b b t k ut f th hi l t h t in r n su h h t he ini n
haft be r m d ( y L nd ruis r fr nt l s f r mpl ) DO NOT r m th s fr m th rri r
but pr d t st p 9 b l
2 Ma k th d ffe t al b i g ps t rient t n nd ide ith un h m k r Als d this is
t ly imp rt nt m k th lef i ht si and r t ti n l p siti n f th b ring djust rs s th t
th n b r inst ll d in tl th s m
2. Pu each ax e shaft out
3. Re ove he s ider ears and s de gear and a
4. Proceed to the section be ow entit ed xaminat on an repara
from he carrie and the r n ea remo e from the case h s p o ess requires emova of the differen-
tia bearing ap an o ter ra es. In s me d ferential the iffer nt a bearin pre loa an r n and pini n
ba k ash a e se by shims wh l n others these values re set by ear n justers Bo h the pre-load
an ba ash m st be o ect for o r i ferent al ass mb y to o erate p oper y A s m ng that y ur
differential has a re y een o er n at sfact r ly the fol o n remo steps a a guide t hel y
re nstal your f erent al ca e into the a rier w thout h ng to measure and se up these v l es again
Be sure to re r to your shop manual fo a d i na n mat n
ine, for ex mp e the sh p manua w usua y ecommend the use f a arge too ca ed a carr er
spreader however, many mechan cs wi nstead remove the ase w t a pr ba Consu your c
nternet s urces or the procedure or you to use
Mark h d fferentia bear n caps s t or entatio
cap o ts and caps.
u out t e a e sh
4. Pry out remove the case As the c se is b
D RE L BEARING IMS note that n some Dana picer axl s t e shims a e located under the
carrier bea ings and thus canno be removed or ost un ess the bearing is pressed off) It is extreme
important to put these sh ms back i the sam cation and order during re-assemb y
Mark the i ferentia bear ng oute races as the case is coming out so t at they can
same sides.
Mark the ri
7. Rem ve he r ng g ar from the case
8. Remove the p nion sh ft retaining pi
9. Remove the pinion shaft
1 Remove the spider gears
11. Proceed to the section be ow entit ed xaminat on and repara
g ar such as n Land Cru ser ear C c ip ax es) do not remove he hird member but refer to C-c p Ax es
or to “Thin R ng ear” above (dep n ing on you p rticu ar design). Otherwise, remove the th d member
r m the vehic e and ace it on the ben h ( ee the shop manua r the step required which wi inc u
pu ing t e ax e ha ts out a few inches disconnecting he drive s aft dr ining the gear and unbo ting
the carrier.
shaft can be r moved (many Land Cru ser front a les, for examp e DO NOT remove t e ca e rom the carr
but proceed to step 9 be ow
extr me y important, mark the eft o r ght side nd rota iona pos t on of the be ing djusters so
they can b re-insta ed in exact y the same ay.
2 P l each x e h f
3 Re ve h ider e r a d d r d
4 P oceed t e ec io belo ntit ed Examin t n Pre a
f h carr e a d t r ea r mo ed f om the c h s r s r i es emo o h di
tia e i g d t r races s m d er nti l the fer n ia in r d n r n pini
b sh a s b him wh l ot er the l re t y r d ers h the re lo d
nd b k h m st r f r o r di fer n l s mb t oper p op r m ng h t yo r
diff rent l h lre d b n o r in at fact r l the follo in remov ep ar uide t el o
r n t l y r iff r nt al c e in o e arr r i h ut h i g t m a u nd se p hes l a ai
Be e to r f r to our sho m n f r ddi i n in m ti n
li e f r ex mple th sh p m nu l w l s a ly r m d th se of l r e ool a ed “carr r
s re d ” how ny mecha c il n t ad remov h s w h pr b C s yo r c
internet s rc for he r ced re for ou u
M rk th d ffe e ti be r g c p s t o i ntatio
cap b lt and c ps
P ll out t e a le sh
4 Pry o t (r mov the c se A th c s s
D FFERE TIAL BE R NG S MS t t n ome Dana picer axl th s i a e l ca d e
c rrier be ing nd t c nno be m e or lo t unless the b ari i pre se ff) It i extr mel
im rtant t pu the e sh m b c i the s me l cation and rder d r ng re a embly
Mark he diffe e t al b r g t r ce as h ca e c mi g t o that h y ca
s m s d s
M rk he rin
7 Rem v h r ng g ar f om the ca e
8 R m ion sh f r t ning pin
9 R m th pini n sh ft
10 R m th spider g ar
11 P oceed t e ec ion belo ntit ed Examinat on Prep r t
g ar ( ch as n nd C uiser ar lip xle ) do no r o he hird membe re r “C- p A es”
or t “Thi R ng Ge ” bo p n ing you p rticu de ign) Other i e r mo th th d membe
fr m e v hicl and lace it on th ben h (Se th shop m nu for he e equi d wh ch ll ncl
p li g the xle h fts ou w in he di conn c i g the d ive s aft r i in the g r il and olting
the carri r )
c be r m d (many L nd Cru er fr nt xl s f r mple) D OT rem v t e c fr m the carr
b t oc ed t tep 9 elow
ext m ly import nt m r h le r g sid nd r ta i n po o o he be r ng djus r
th can b r in tall n exactl th me y

3. Rock the ring gear back and forth to get a feel for the amount of ba klash pre ent (usually around .008).
This step will allow you to check during re-assembly that the bearing adjusters are in their correct
positions and are not one turn off. (When in doubt use a dial indicator and stand to measure the before
and after backlash).
4. Remove the adjuster locks, bearing cap bolts and caps.
5. Mark the diff rential b a ing races so that they can be re-installed on the same side.
6. Lift the differenti l case from the third member.
7. Mark the ring gear in relation to the differential case.
8. R th ring gear
9. Remo e pinion shaft.
10. Remove he spid r gears and side gears and all thrust washers.
11. Proceed to the next section entitled Examination and Preparation of the Parts.
EXAMINATION AND PREPARATION OF THE PARTS AND THE DIFFERENTIAL CASE—ALL MODELS
EXAMINATION OF THE PARTS
1. Check the tw large side gear thrust washers for wear, cracks, warping or galling If they are not in
e cellent cond tion, replace them The small washers under the spider gears will not be used.
2. Examine the pinion shaft. If it is worn by more than .002 where the side gears were located, purchase a
new one from your dealer.
3. Check the hardness of the pinion shaft. In many instances we have found that the stock factory shaft is
somewhat soft. Try to scratch a groove in it with a file near the center. If you can do so, the shaft is
soft. If the file tends to slide and not cut, the shaft hardnes is probably ac eptable. If it is soft r place
it, and also be sure to check the new shaft. If the old shaft is worn under the spider gears, definitely
replace it.
4. Thoroughly clean the differential housi g to remove any old dirt and metal particles.
5. If the installat on is in the front d fferential, now would be the time to inspect/replace the inne axle seals.
6. Examine the differential case and earings. If there are any chips or cracks n the case, and/or the
b ar ngs are worn, replace them—but remember that the ring and pinion backlash and bearing pre-load will
need to be set up again.
7. If your differential has a thrust block and it is to be re-used (Jeep AMC-20, for example), examine the
block and be sure that it is in good condition. If it needs to be replaced, be sure to set up the axle shaft
end-play again (see your shop manual).
CHECKING CASE TOLERANCES
1. Apply a thin coat of medium to heavy axle grease to the teeth of the Aussie
Locker axle gears, to the back surface and around the hub in the center.
Using thisgrease will help with holding the parts in place later on.
2. Place a thrust washer on each axle ge r.
3. Install both axle gears in the differential case.
4. Place a spacer onto each axle gear, with th open end over the hub of
the axle gear. The grease will hold it in place.
5. Carefully slide the pinion shaft all the way into the case (past the
spacers).
6. With a screwdr ver, carefully pry apart the gap between the spacers and the pinion shaft. This step will
compress out the grease and help assure that the following measurement is accurate.
Th s tep wi l allow you o check dur ng e ass m ly t at the bearing adjusters ar n the r correct
posi ions a d are not one urn o f. (Wh n in doubt use a dial ndicato and stand o measu e the b
and after bac lash .
Remove he adjus e
5. Mark the dif erential bearing races o that th y c n be
6. Lift t e d ferentia c se from the third member.
7. Ma k the ring gear in relation to the d fferentia
8. Rem ve the r ng gear
9. Remove the pinion sh
1 Remove the spider gear
11. Proceed to the nex sect n entitled Examinat on and Preparati
exce l nt cond tion, ep ace them The small was ers nder th spider gea s w ll n t be u ed.
Examine he pinion shaft I t is worn by more than . 02 where the side ge r were l cated
new one from our deale
Che k the hardness of th
somewhat soft. Try o scratch a groove n t with a file ne r he center. If you can do so the sh ft is
soft If the file ends to slide nd not cut the sh ft ha dness is robab cceptab e f i is soft rep
it, a d also be sure to check he new shaf . f the o d shaft is worn unde the spider ear efin tely
r lace it.
horou h
5. If the insta ation is in the ront differential, now wou d e the t me o nspect/repla
6. Exam ne the d ffere t al case and bearings If there ar any ch ps or cracks in he case a d/or the
bearings are worn repla e th m—but reme ber that the ring and pinion backlash and b ar ng pre-l
need to be set up again
If yo r di ferentia has a
block nd be sure that i s in good condi on. If it needs to be replace , be s re to set p the axle sh
end-p ay ga n ( ee your shop manual
Locke xle gear , to the back surface and around the hub in he center.
Using h sg ease will help with holding the parts in pla e la er on.
P ace a th u t washe on each axle ge r.
3. Insta oth ax e gear in the d fferential
4. Place spa er onto each axle gear, with the
the a l gear. he g ease wi l hold i p ace
Carefu ly slid he pinion sha t a l the ay in
spacers)
With a c
com r ss ou the g ease and he assure t at he fo low ng measurement is a cura e

7. Using feeler gauges, measure the gap between the spacers and the
pinion shaft. For each spacer it should be between .006 and .020.
If it is within tolerance, remove the pinion shaft and only the spacers
for use later. If it is not within tolerance, either the case is worn or the
thrust washers are worn. The locker needs to have this gap within
tolerance to operate properly.
Failure to ensure the proper tolerances will show up in marks on the
locker components and will void the warranty.
8. Remove the pinion shaft and spacers, but leave the axle gears and
thrust washers in place.
PREPARING THE REMAINDER OF THE PARTS
1. Be sure that your work area is clean and that no
dirt or metal particles are present and that the
grease is clean and free from contaminants.
2. Apply some grease to the teeth of the cam
gears, to the slots for the p ns, and to the hole
in the center. The grease will help hold the parts
in place and will lubricate them until the gear oil
circulates.
3. Apply a small amount of grease to the pins and
springs.
4. Install a pin into each of the long slots in the
cam gears. Be sure to posit on the step on the
pin toward the bottom of the slot, toward the
teeth (later, the spr ng will snap over the step).
5. Install a spacer in the center of each cam gear.
Orient the spacer so that it will fit down over
the hub in the center of the axle gear when
installed (the same way as when the clearances
were checked).
INSTALLATION OF THE AUSSIE LOCKER
C-CLIP AXLES
PREPARATION
Make a small tool from a 6" piece of coat hanger wire. Form it in a wide “U” with the ends bent up by
about one inch, and a 4" middle portion. This tool will help with moving one of the spacers sideways while
installing the right C-clip.
INSTALL THE LEFT SIDE C-CLIP AND FIRST CAM GEAR
1. The axle gears and thrust washers should already be in place from checking the tolerances. Carefully push
in the ring gear side axle shaft, through the axle gear splines.
2. Install the C clip on the end of the axle shaft, with the points facing downward
3. Pull (snap) the axle shaft outward to seat the C-clip onto the hub of the axle gear.
4. Carefully insert one of the cam gear assemblies into the case with the teeth oriented toward the axle gear.
5. Push the cam gear teeth nto the axle gear teeth so that the grease “squishes” out.
6. Reach into the center and push the spacer down over the C-clip and axle end. The combination of grease
and the spacer over the hub should help hold the cam gear in place.
p nion shaft For eac spacer t should be between. 006 and . 20.
If t i w th tol rance, remove the pi ion sha t and on th pa
f r use ate . f it is no within to erance, e the he ase worn r h
thr st wa h s are or The ocker ee s t ha e hi ga w th n
tolera ce t operate pr erly.
Fa lure to ensure the proper t
locker com onen s and w ll vo d the war a ty
Remo e the p nion sha a d spacers b lea
thr st washers n lace
dir or me al part cles e present a d tha the
greas s c ean and f e rom contaminant
Apply ome gr ase to the teeth o the cam
gears o the lots r the ins and to the
in he center. The re se will he p hold the part
in pla e and ill lubricate them un l th gear oi
c c l t s
Appl a sm
prings.
Instal
cam g ars Be s re t p s tion the ste n th
pin towar he bott m of the l t toward the
tee h ( ate the spring w l sn p over t e s ep
Insta a p cer n the cen er of each cam ear
Orien he spacer that t ll it d n o er
the h b in the ce te o t ax e ear hen
i sta led ( he me wa as hen the leara
were che ked)
abou one in a d a 4 mi dle po t n. This tool il he p w th vin one of he sp e s sid way while
install ng t e r h C c ip
n the r ng gea s de axle haft thro gh the axle gear splines.
s al the C-c p on he nd o t e axle sha t w th the p int
3. Pull (snap he axle sha t o ard o sea the C-clip onto the hub of the ax e ge
4. Care ul y nser one f th cam gear ssem i into the case with the teeth orient
5. Push t e cam ear eet into the ax e gear teet so tha he grea e “ qui hes” out
6. Reach n o the cen er and p h the spacer down o er th C- lip and xle end. he
and the spacer over t e h b s ld help h ld the cam gear n pl ce.

INSTALL THE RIGHT SIDE C-CLIP AND SECOND CAM GEAR
1. Insert the second cam gear assembly into the case, with its teeth facing the axle gear. Hold it toward the
middle of the case, touching the left cam gear.
2. Holding the right cam gear leftward next to the left cam gear, reach into the gap between the teeth (of
the right cam gear and axle gear) w th the “U” shaped tool made earlier. Twist it to slide the spacer to the
LEFT, partially into the left cam gear. The right cam gea will now be centered on the spacer and touching
the left cam gear, with a gap between the right-hand teeth
3. Remove the tool. Everything should just sit there, held n place by the spacers and the grease. If not, the
assembly may need to be held in place during the following steps
4. With the left axle, slowly rotate the complete locker assembly until the C-clip recess in the right cam gear
teeth faces toward you
5. CAREFULLY slide in the right axle shaft. Hold the right axle gear so that it doesn’t slide out of place as the
axle spl ne comes through.
6. Look through the gap between the teeth as the axle end begins to protrude from the axle gear hub. Stop
sliding the axle shaft when its C-clip groove is comp etely visible
7. Carefully inse t the second C-clip nto the groove. The grease will help hold it in place.
8. Pull (snap) the axle shaft outward to seat the C clip.
9. Rotate the right tire 1/4 turn until the C clip points face downward, which will help keep it in place while
the cam gear and spacer are being moved nto pos tion.
10. Carefully move the r ght cam gear to the right and seat it into the grease in the axle gear teeth. The
spacer may remain stationary for the moment.
11. If the spacer s “stuck” to the other spacer because of the grease, use a small knife to pry them apart.
Reach in through the pinion shaft recess in the axle gears and slide the spacer to the right, onto the right
axle gear and over the C-clip and axle end.
ASSEMBLE THE PINS AND SPRINGS
1. Rotate both halves until the cam gear recesses line up. This
also lines up the pin and spring holes.
2. Push one pin from the ong s ot across the gap and into the
opposite cam gear pin hole. The visible end of the pin should
have the small step on it.
3. Insert a spring into the slot just vacated by the pin. One end
of the spring will fit over the step on the end of the pin and
the other end wil nest in the bottom of the slot.
4. Carefully rotate the whole locker assembly to expose the
next slot. Repeat steps 2 and 3 three more times. Assembly
of the locker itself is now complete.
MEASURING THE CENTER GAP
This step is important because it relates to warranty issues. The gap down the center of the locker must
be within tolerance for the unit to operate properly. If it s too narrow it can bind up, and if it is too loose
the cam gears ca become damaged. Therefore, you will need to measure how far apart the cam gears
at the middle of the assembly are. If you have a warranty claim we will ask you for this informa
tion. If we receive the parts back we can tell if the unit was operated out of tolerance by the contact
patterns, and this can void your warranty.
m dd o he case, touch n he eft cam gear
o din the r ght c m gear e ward nex o th
the r g t cam ge r an ax gea ) w h e U haped too de ea ie wi it o s e e s acer t
L, pa ia nt t e e t am g ar. he ght cam gear w now be cente e on e spacer and touching
the t cam gear, with a g etwee the gh han teet
Remov the too . ver t ng shou d just s there, he d n p
asse b y may n e to be he d in p ace during the o owing steps
W h the e t ax e, s owly otate the com e e oc er assemb un
teet faces o a you.
CA U LY s de in he
ax e sp ine come rough.
Loo throug the gap et
s i g the ax e s a hen ts -c ip groove is c mp ete y vis b e
Care u y i se t the second C c p n o the g oo e he gr ase w
8 u (snap) the ax e sha out ar to sea t e C ip
9 t te he rig re 1/4 t rn unt h C c ip poi s
the cam gea and space a e e ng mov nto po ition.
Care u mo e the ight ca gear to e ight and sea
space ma remain stati ar o the moment
I the pacer is s ck to the ot er pace be
Reac in thr u h the nion sha t recess in the ax e gears and s d the pacer to the r g onto he rig
ax e g a a d ov r t e c i and ax e end
a so nes up the p n and sp ng h e .
Pus one pin rom the o g o ac o
opposite ca gear pin ho e The visib e en o he p n s ou
have the sma step o .
Inse t a pring nto the s
o e s ring w f t ove th ste on the end o he pin an
he othe en w nest the bo o o he s ot
Care u y ota e the w o ocker ass mb y o ex
next s ot epe t st s 2 nd 3 t ree more t mes As em
o the ocker t e is n w comp ete.
hi i i i
be wi hin o erance o t e uni t opera e oper y i s t o na ro i an bind up, nd i i s too oo e
the a ears can be ome amaged. here ore y u w l nee o easure h w r p r th cam ge rs
at t e m dd e f the assem y are. If ou have warranty claim we will as you for this informa-
i n we ece ve e parts bac we ca te i he unit was operated out o to erance by t e contac
patt n , a d this can o d y ur w rranty
m ddl f he case, to chin the left cam gear
Holding t e r ght c m gea leftward next to h
the r h cam ge r and axl gea ) w th the U” haped t ol m de ea ier. Twi t it o s ide the spacer o t
LEFT, rtially int the left am ar he righ cam gear ll now be ce ered o t e spacer and touching
the l t cam gear ith a g p be wee he righ -ha d tee h
Remov he ool. ery hing shou d j s s there e d in pl
assembly ma n ed to be e d n p ace dur g the lowi g st ps.
W th the ef axle s ly tate the comp ete locker as emb y un
tee h faces toward ou
CARE ULLY lide n the r
axle plin ome thr ugh.
ook thr ugh the gap bet
s id n the ax e shaft when its C-clip gro ve s completely vis e
Carefu l i sert the ec n C-clip n o the g oove The gr a e wi
. Pu l (snap the ax e shaft o tward to eat the -
9. Rot e the ri h tire 1/4 turn unt l he C-c p points f
the cam gear a pace are being moved nto posi on.
Care ully mo e the right cam gear the ight and sea
spacer may rema n stat na y for the moment
I he acer i “stuck” o he ot er acer be
Reach in thr u the ion shaft r cess in the axle gears and sl d the pacer to the r ght ont he ri
ax e gea and over the -cl and axle end
a so l nes u the pi and r ng h les.
Push ne pin from the long slo acro
opp si e cam gear p n hole Th visib e end of he p shoul
have the ma l s ep n it
Inser a pr ng into he
of the spring w l fit ove h step on the end of the pin and
the other en est i he bottom of he s ot
Caref lly rota e the wh le ocker assemb o ex
next sl t Repeat st p 2 and t ree more times. As em
of the ocker itse is n w c mp ete.
e within to erance fo the nit t opera e roperly it is t narrow it can bind up nd if i oo ose
th ca ears can e m dama ed Therefore y u w ll need t mea re h w ar apar t cam ears
a the d le f the assem ly are. If ou h ve warra t c ai we i l ask y u fo thi nf rm -
ti n f we r ce ve he parts ac we ca tell i he unit w s operated out of tolera ce by the contact
patt n a d this an o d ur w rranty

1. Using a feeler gauge or dial caliper, measure the center gap. It should be between .145 and .170 wide. If it
is outside these numbers either the case or thrust washers are worn or possibly other (thicker) thrust
washers were installed at one time. If the gap between the spacer and pinion shaft is O.K and this
measurement is not within tolerance, re-check your installation to see if anything is out of place or if a
piece of metal or dirt may be stuck somewhere.
2. Measure the center gap before buttoning everything up in case the thrust washers, etc. are bad.
3. Write the gap measurement on the form in back of this manual. IF YOU HAVE A WARRANTY ISSUE WE MUST
HAVE THIS INSTALLATION INFORMATION.
INSTALL THE PINION SHAFT
(C-CLIP/THIN RING GEAR AXLES)
1. Rotate the drive shaft to position the differential case so that
the pinion shaft hole points downward at about a 45°angle so
that the pinion shaft can be inserted, and with the pinion shaft
retaining lock hole exposed
2. With either axle shaft, rotate the locker assembly until the cam
gear recesses line up with the pinion shaft holes.
3. Carefully slide the pinion shaft into the case, past the spacers
and into the opposite side.
4. Line up the pinion shaft lock hole and install the lock pin or bolt.
5. Proceed to the above entitled Measuring the Center Gap, and
then to the section below entitled Testing the Locker Assembly.
THIN RING GEAR
This portion of the instructions assumes that the differential case has remained in the carrier, whether or
not the carrier is in the vehicle. If your differential is in a removable third member that is on the bench,
perform the following installation there and then re-install the third member in the vehicle.
1. Prepare all the parts for assembly as described above under
Preparing the Remainder of the Parts. The axle
gears and thrust washers should already be in place from checking the case tolerances
NOTE: If your assembly will re-use the thrust block (Jeep AMC-20, for example), insert the thrust block into
the splines in the right axle gear. It will be pushed inward later with a tool or with the axle shaft.
2. Install the left (ring gear side) cam gear assembly onto the left axle gear with the teeth meshed. Push it in
so that the grease “squishes” out.
3. Reach into the center and push the spacer to the left, over the axle gear hub.
4. Install the right cam gear assembly into the case onto the right axle gear with the teeth meshed.
5. Rotate the left and right halves until the large cam gear recesses line up. Reach inside and push the right
spacer to the right, over the axle gear hub.
6. With the cam gear recesses lined up, slide one of the pins in either cam gear across the center gap into
the hole in the opposite cam gear. The step should now be visible on the top of the pin.
7. Insert a spring into the slot on the cam gear just vacated by the pin. One end should nest into the bottom
of the slot and the other end should snap over the step on the end of the pin.
8. Repeat step 7 for the remaining three pins and springs. The assembly of the locker itself is now complete.
9 Proceed to the above entitled Measuring the Center Gap
10. Rotate the differential case so that the pinion shaft hole and lock pin holes are visible.
NOTE: If your assembly has the thrust block inserted in the right axle gear, before performing the next step
use the axle shaft or a tool such as a rake handle and carefully push the block into the center. Line up its hole
with the pinion shaft hole and then proceed to the next step.
11. Carefully insert the pinion shaft into the case, past the spacers. Line up the pinion shaft lock hole and
install the lock pin or bolt.
12. Install the axle shafts, bearing retainers and backing plates (if applicable). If your assembly uses a thrust
block, be sure that the axle shaft end play is set up correctly.
13. Install the tires. They will be needed for testing your assembly once everything is buttoned up. Don’t
forget to tighten up the lug nuts later on.
14. Proceed to the section below entitled Testing the Locker Assembly.
is t i t e e num s e her the c e or th t as ers re w n or p ib e ( h ck r t r st
w hers re n t ed t on t m f th bet en t e s ac r d p nion haft is nd
me u e t ot i hi t l r c check in ll t on o s f n i g i t f p ce r
ece o met o dir y t c s er
Meas r th c n er g b fo b t n g er
3 Wr te t m rement he fo m in b c of hi m a I OU HAV ARR N I UE
E T IS IN TA LATION NFORMATION
I S HE I IO SH
(C CLIP HIN RING GEAR AX ES)
th pin o h f e p i t d w r abo t a 45°n so
tha t n n aft ca b ins t d n ith h p i n sh f
r t n l c o xpo d
W th ei h r x haft r tat
ar r c s e i th th i on sh ft hol
ar f ll l d t e pi i n h f i to c pa
an to h o p t id
e p th inion h ft loc
5 Pr c e t h a v i l Me s r ng th Ce t G nd
then t h tion l w nt l d Te t n h L ck s mb
HI I G GE
i i i i i i l i i i
t he c rrie i i h hi l If r differe tial i in r o bl hird emb r th i o th b n h
er orm th f llo i i llati her d r i ll h third m b in he hicle
ars d h st a s sh l lr ad e in ce f om c ki h ca t e nc s
h s ne n h r ht e r It il b p s ed in rd lat it o l r wi he axl ft
s th gr a “squ h ” t
R ch t h c n an p h th
4 ta l t i h c m e r a s b nto h c n th g t axle gear ith
5 Rot t t e f nd ght ha s nt e l r e c m r ece es l n p R ac in ide p h
p cer t t e r g t ov r h ax e g h b
With t e am e r ece ned up de
h o e n th op site cam ea T te h u d w s n t top f the i
s rt i g int th lot n th m ge r ju t v c t d b th i On end h d
of th s ot d e t er end d s p o er the tep o t e t e p
R p a te 7 o t re a i th ee in d s r gs h embl f the
9 Pro ee to t abo e n tl M rin t e C nt G
0 R tate t e d ff rent a c e that t p n o h ft ole
u t l aft r l h ra dl and ca f ly p he b ock i t th n er in p it h
ith th in o s ft h nd t en pr c d t th e t t p
ns a l t oc i r l
ta t e ax f b
b ock b h t th xl h ft e d p a i t p c r ct y
st th tire Th ll b de f r t ti u em l
f rget t g te t g ts lat
Pr ce d o t e ct b lo en led

THICK RING GEAR
ASSEMBLE THE DIFFERENTIAL CASE
1. Perform steps 1 - 10 immediately above under Thin Ring Gear to install the locker into the differential case.
It is assumed that the case is bare and on the bench, with the axle gears and thrust washers in place
from ch king case tolerances
2. I stall he ring gear on the case. Be sure to orient it according to the marks made previously, and tighten
th bolts s utlined in your shop manual.
3. Proceed to the section immediately below that applies to your differential design.
INSTALL THE DIFFERENTIAL CASE—INTEGRAL CARRIER
1. The differenti l case and ring gear assembly is now ready to be installed i the carrier Using the sh ms
marked and removed previously, install the case into the carrier using the methodology determined from
y r shop manual and club nd internet sources This will generally involve using a carri r spreader, or
pounding it in with a brass m llet. Be sure to locate the bearing races on the correct side, and watch the
shims as the bearings enter he sea s.
2. Install bearing aps and torque the bolts or nuts.
3. Install the axle hafts, bearing retainers and backing plates (if applicable).
4. Proceed to the section below entitled Testing the Locker Assembly.
INSTALL THE DIFFERENTIAL CASE—REMOVABLE CARRIER (THIRD MEMBER)
1. This section assumes that y ur assembly uses bearing adj sters t set b cklash and pre-load and that
these parts were marked and removed as described above u der Removable Carrier (Third M mber). If your
unit is of nother design, consult your shop manual for the procedure used to install the differential case
int the carrier
2. The differential case and ring ge r assembly is now ready to be installed in the carrier. Place the marked
bearing rac s n the c rrect sides.
3. Set the ase and bearing rac ssembly into the bearing seats in the carrier.
4. Place the m rked adjusters into the threads on th correct sides.
5. Install the marked caps and the bolts. Snug the bolts down but do not tighten them yet so that the
adjusters will still rotate
6. R tate the left (ring ge r side) adjuster inward until it stops and the ring and pinion backlash is zero (the
ing gear is ligh ly jammed into he pinion)
7. Back off the left adjuster until it reaches the position marked previously. This is now the exact orientation
where i was l cated originally
8. Rotate the right adjuster i ward It will become difficult as the correct pre-load is approached. Continue
tur ing until it reaches its marked orientation.
9. Tighte the bearing cap bolts to the torque s ecs defined in your hop manual. If you re-positioned
everything to the marks made during dis ssembly, the R&P backlash and bearing p e-load should e exactly
the same as before the installation beg . To do a rough che k, rock the ring gear back and forth. It
shou d have the same “feel” as before–about .008 or so. If not, don’t despair–just set them up again using
the shop manual procedures.
NOTE: You may need a d ff shop to do it, because the b klash and re-load e especi lly imp rtant and
need sp ialized knowledge. However, at this point it’s not quite as bad as starting from scratch because the
pinion depth is already correct.
10. Install the third member into the vehicle. Use a carrier gasket and RTV as needed, and tighten the nuts
per your shop manual.
11. In tall the axle shafts, bearing retainers and backing plates (if applicable).
12. Fa ten the drive shaft to the yoke.
13. Inst ll the tires They wi l be needed for testing your assembly once everything is buttoned up. Don’t
forget to tig ten up the lug nuts later on.
14. Pr ceed to the bove entitled Measuring the Center Gap, and then to the section below entitled Testing
the Locker Assembly.
THICK RING GE R
SSEMBLE THE DIFFERENTI L C SE
I s h s s n n h n h th r n h t s n
fr m h n s t r n
I s h r ng n th s
n n sh m n
Pr h t n mm
INST LL THE DIFFERENTI L C SE INTEGR L C RRIER
m k n r r us st h h c r r n h h t rm n
r sh m n n n n r s Th n n s n r s
n n t r s m t th e n n th o r t h
sh ms s h s nt r h ts
Ins th r n s n r h
h ft t n r n n
Pr t th t n e t t T st n h o k m
INST LL THE DIFFERENTI L C SE REMO BLE C RRIER (THIRD MEMBER)
j
h r r n m s b n r m r T r M m f
n f h n n r sh m n f r h r r s h f n
n h
Th ff
n r n th r
h s n r n r ss
h m r j te s n h h s th e s
In th m k th Sn h s n t
j t r t t
Rot t th f r n j
n mm n he n n
ff h ef dj s r n h
h t n
t r h j s r n
n n nt t h t r n n
T t n th r n s s
e t n t th m k m n s s m th R k h r n r h
h m s f r t n t t n n T h h r h r n e k f rth It
h h s m “ ” s f r r s f n t t s – u n
h s m n
n r th n s n t s s s n fr m h
n th s rr t
r s m n
In t x sh f
F n th h f t y k
In h r Th
f r t t ts t
c t nt t r n
h r ss m
It s med the c se s ba nd on he n h th the x e ge r n th t s ers n c
f m ch c ng c se to r n es
I st th r ng e on the c
t e bo s u lin n yo sho m nu
Procee o e ct on mm d te y b ow
m ke n re ov re u ly st the c nt th c r er u ng the ethodo gy eterm n d
y ur sh p m n n c u n t rne ou ces Th s gene nvo ve n ca er s de or
p d n t n w t r ss m et B s re to oc t the e n races on the co rect s de d w t h
sh m h gs enter the s s
Inst th be r n ca s n or ue h
x e h t r et n r n b k ng
4 Proce to th ect o e w e t t Test n th ocker A sembly
the p r s er r e n rem ve s esc bed bove nder Re ov b e C rr e (Th r ember) f y
n t f oth es gn c n t y shop m n f th roce ure s t t the d f ent a c s
nto th r
The ffe e t
e n r ce n the c r ect sides
Set he c e r r ss
4 P ce th m rked djusters n o the th o th c rect s de
5 In t th m k ca the o s Sn g th o ow ut
d ters t rotate
Rot te the f (r n ge
e t amm nto the p n)
B c off h ef ad uster unt reach t
whe t w o te or
R t te he djust r n a
t rn ng unt it re ches t rke o en t n
T ten the r ng c b ts to t e torque s
veryt t the m ks e r n d s emb y the R&P a k h an b r r - ho d be
th s me a efor t n t t on b g n To do u h ch ck roc the r n ea b ck o t t
sho d h ve the s me “ e ” s ef – 008 so f not on t s r– u t et th up g n
th sh m nu r ce re
n e c ze know ed Ho e t th o nt t’s n t q t s b d s s t ng from s r tc ec
n d th s re d corre t
p yo r s o m nu
In a t e x sh ts
F ten the d v h f to t y ke
In t the r s They n e e
for et t t te p t ts te
Pr cee t e bov ent tl M sur n
the ock Assemb y
It is assumed t the case s ba e and n the ben h, w h the axle gears and thrust washers n place
from checking case to eran e .
Insta l the ring gear on the cas
the bo ts as ou lined in you sho m nual
Proceed o he section mm diat y below
marked and remove prev ously, sta l the case into the carr er using the meth dolog determined from
your sh p manual and club and nterne sources This wi l genera ly nvolve using a carrier spreader r
pounding t in wit a brass mal et. Be sure to locate the ear ng races on the co rect side, and wat h
shims as he bearings enter the s ats
Instal the bearing caps and torque th
3. Install the ax e shafts, bea ing reta ner and ba king
4. Proceed to the sectio below entitled esting the ocker Assembly
these parts ere mar ed and removed as described above under Removable Carr er ( hir Member) f
unit is of anothe design consult your sh p manua for the procedure used o insta l the d fferent a case
into the ar ier.
he di ferential
bea ing races on the cor ect ides
Set he case nd bearing race asse
4. P a e the marked adjusters in o the threads on the cor ect sides
5. Insta l th marke caps an the bol s Snug th bo ts down but
adjusters il still rotate
Ro ate the e (r ng gear
ring gear is ightl jammed nto the pinio
Bac off he left adjuster until t reaches th
where it was located orig nall
Ro a e the right ad uster nwar
turning un i it r aches it marke o ien ation
Tighten the bearing cap bolts to the torque s
everyth ng o the marks made during disassemb y the R&P back sh and bearin pre-load shou d be
the same as before the nstallation began. To do rough check rock the ring gear back nd for h t
shou d have the same eel as bef re–ab ut 008 or so. f not on t despai – ust et them up aga
the shop manua procedure
need s ecialize knowledge. Howe er a th s point it s not quite as bad as s arting from scratch because
pinion dep h is a ready corre t.
per your shop manual.
Ins all t e axle shafts
12. Faste the dr ve shaft to the yoke.
13. Insta l the ires. They wil be neede
forget to t ghten up t e l g nuts later on.
Proce d o the a ove entitl d M asur ng
the Locker Assembl .

TESTING THE LOCKER ASSEMBLY
This section assumes that your new Aussie Locker has been installed and that the complete differential
assembly is now in the vehicle with the tires installed.
1. Put the transmission in gear and the transfer case in 4WD to lock the drive shaft. Tires must be installed
to complete this test.
2. Rotate one of the tires until it stops against the locked drive shaft. Hold it in position and maintain
moderate pressure
3. Rotate the other tire in the opposite direction. It should unlock and spin, with the locker clicking as the
tire rotates Note that this sound will be less with the cover on and gear oil inside.
4. Rotate the first tire in the opposite direction until it stops, and again maintain pressure
5. Rotate the second tire in the opposite direction from the first time. It should again unlock and spin with
the cl cking sound.
6. Switch tires. Rotate and hold the second tire, and spin the first one in the opposite direction. Again switch
directions. Both tires should rotate in both directions and the locker should click as they are doing so.
7. If your installation passes this “spin” test, you are ready to finish up.
COMPLETING YOUR ASSEMBLY
1. Install the cover, using RTV and/or a gasket as required.
2. Add gear oil to the proper level.
3. Check to be sure that the backing plates and retainers (if applicable) and brake lines have been installed
and tightened correctly. If you have pinched off the break lines, be sure to release them.
4. Leave the vehicle in gear, and apply the emergency brake. Remove the jack stands and front wheel blocks.
TESTING YOUR VEHICLE
1. After your installation is complete and tested as described above, it’s time to take your vehicle for a spin.
Consult the Operator’s Guide for detailed information on how to operate your vehicle on and off-road.
2. During your initial testing, take it easy for the first few miles. Remember that your new locker-equipped
vehicle will now climb walls but that it also has some different handling characteristics. Take turns slowly
at first. Remember that if you power around a turn that the inside (powered) wheel will spin up more easily
than before because weight s transferring off it as the vehicle leans outward.
3. Dr ve it around town for a while, and then take it off road on a level surface to get a feel for how it
behaves in dirt Be careful, and have fun!
4. There is a break-in period for your locker of about 600 miles In a very few nstances you may notice some
noise other than clicking while turning during this time. If you have installed your locker per these
instructions, there is no need to be concerned about these additional sounds.
assembly is now the eh cle th t e t re install
to complete this test
Rotate one o the tires
moder te pre re.
Rotate the other ir
tire rotate Not that h s ound wi be less it the cover on a d gear oi ins e
Rota e the f rst tire n he pposite d ec ion until t stops and gain mainta n pres
5. Rotate the sec d t re i he opposite direct o fr m the st t me. sh uld again un o
the click ng so d
Sw ch tires. Rota
direct ons. B th ire sh ld tate in both directions and the locker sh ld click as hey are oing so
If o r in a lation pa es th “spi ” e t ou are eady o fi ish u .
2. Add gear oil to t e proper l vel.
3. Check o be s re t at the back
a d ti htened correct y I yo ha e p nched off the brea ines be sure o elease t em
ea e the veh c e in ge , nd apply the emergency brake Rem ve the jac stands and f
Consul the Operator’ Guide for detai ed info mation on h w to o er te o r ehicle on- a d o f-r ad
Du ng our initi l te t ng, take i easy fo the t e m les. Remember that our new lo ker e u ppe
vehic e will n w cl mb wa but that it also has some iffere t handl ng har cteri t cs Take turns slow
at f rst. Remember th t if you ower ound a ur tha the in de (p wered whee wil spin p mo e eas
han b fore becau e w i ht i trans errin o f it as the eh cle leans outwar .
Drive it aro nd own for a hi e an then ake off road on a level s r ace t
behave n dirt Be careful and a e f n
There is a break-in period or your lo ker
oise t er than cl cking whil ur ng d ri g this ime If you h ve ins al ed our locker pe these
ins ruct n the e is no need o be concerned about t e e add tional sound

NOTES
1. The Aussie Locker is slightly larger, and therefore, stronger, than some other units on the market today. In
a very few instances we have seen flashing on the differential case in the area of 2mm that m ght be
evident when you install the second came gear. A round file should be used to remove this flashing. Be
sure to remove any file shavings from the grease and diff.
2. In some Toyota differentials it may be necessary to file down casting flashing and case irregularities prior
to fitting parts.
3. Some Ford Dana 44 front installations may require minor grinding in the case to ensure a proper fit.
a very few nstances we have seen las ing on th d fferent al case n he ar a of mm hat might be
e ident whe you in tal the second ame gear A rou d file s ould e used to emo e this f ashi g B
sure t emove any ile shav ng from the grea e and di f
In some Toyota d fferent als t ma be necessary o fi e do
to f tt ng part .
Some Fo d Da
4. Yo can con act us a :