aussie install tips

there are a few tools you must have to do this that most of yall probably dont have..........
and a couple of them everyone who wheels a jk shoud have in their trail tools

the complete list of tools required..........

lug wrench
13/16th socket
13mm 12point racheting box wrench...................must have............trail kit
35mm socket..................must have ................trail kit
5/8th socket
big pry bar
big deadblow hammer
feeler gauges
dial caliper................not absolutly nessisary but nice to have
3/16 punch or rod

ok now im going to walk ya through it

this first part is also how to remove the axle shafts for u-joint repair or shaft replacement or just to get you home if you broke something bad

jack up the jeep and support it as high as possible by the frame so you have some room to work

remove tires and wheels

remove the (2) 13/16th bolts that hold the calipers to the knukle, and hang the caliper on the lower control arm...............repeat on the other side

remove both brake rotors and sit them inside the jeep so the dont get anything on them

remove the 35mm nut that holds the axle shaft to the hub on both sides and use a large drift and hammer to push the shaft back a little just to make sure it isnt siezed into the hub

remove the (3) 13mm bolts per side with your shiny new ratcheting wrench.....these hold the hub (unit bearing) to the knukle

now this is the hard part...........the hub is going to be stuck on pretty good...............a bolt can be put back in a little and pounded on ......not the best method..........
or you can get out your slide hammer and hub puller and pop it off.......or remount the tire and wheel and wiggle and pull

it will come apart.............

now slide the axles on out.......this is a good time to check the u-joints..........mine were ok but mudhounds were both completly destroyed along with one of his unit bearings.........

now remove the diff cover............13mm socket, and a catch pan

clean the caps with brake cleaner and mark their position, now remove the caps with a 5/8th socket

time to pull the carrier!!! it might be real tight, but pry it on out ...............the bearing races and preload shims are going to fall out too............and they have to go back in exactly as the came out, i cant stress this enough............the must go back on the side they came out of

mark position and unbolt the ring gear and remove it

now drift the 6mm roll pin out of the carrier and the cross pin will push out........remove the side and spider gears but save the thrust washers from the side gears


ok install the locker side gears, then the spacers and cam gear...........slide in cross shaft

measure gap between the shaft and spacers with the feeler gauge..........should be around .007

remove cross shaft.....install pins and springs

the center gap should be between .145 and .180

.........reinstall cross shaft then roll pin and ring gear torque to 60 ft/lbs

pound carrier back into center section and reassemble




go wheeling

Great write-up but one problem

NO PICTURES!!!

drift, mark positions??? what language you speak??

Now, I know for a fact that was a foreign language to me. But even if you wrote it in Dutch, I would still be lost. :hypnotized:

I feel like a nobody next to someone that knows as much about vehicles like you do.
I will soak up the knowledge as much I can. But I think I'll have someone else install my lockers when I get to them on my "never-ending" mod list.

Great write up, pictures would help.

Here is the Aussie Installation Manual


http://www.offroadlockers.com/display/Manual_c.pdf

Paul08Wrangler wrote:

Here is the Aussie Installation Manual


http://www.offroadlockers.com/display/Manual_c.pdf

hey that was easier than what i did.....................

but that manual was kinda hard to read.......at least for me .......and dosent tell you bolt sizes and such........

thanks for posting that for everyone

Thanks guys for posting the write up an links. Maybe at some point if anyone has an old axle, they can bring it to an install meet and somebody can show everyone how it`s done. Nothin like a little hands on.

hey adam, can you move this thread into the write-up section?

Redneck, great write-up. maybe you could bring yourself down here again in June or July and do an install on someone's front diff (hey why not mine?? ) so we could all take pics. maybe gas/food/and a place to stay could be thrown your way?? maybe i got something in my garage you need. donno, i got a tan dash and front door panels for and 97-03 f150 pickup truck. LMK what'cha think.

Great write up, this is on Marhalls list I think he will be getting these next, he just spent $1200.00 at Poison Spider for fenders, I am getting him a stinger front bumper for his BD, and last on the list...well not last it never ends ...are the aussie lockers for the rear.

While I'm here let me ask.

He has ARB lockers in the front, he broke the back, when he gets Aussie's for the back can he still run the ARB's in front or does he need to change that out too?

Renee10 wrote:

Great write up, this is on Marhalls list I think he will be getting these next, he just spent $1200.00 at Poison Spider for fenders, I am getting him a stinger front bumper for his BD, and last on the list...well not last it never ends ...are the aussie lockers for the rear.

While I'm here let me ask.

He has ARB lockers in the front, he broke the back, when he gets Aussie's for the back can he still run the ARB's in front or does he need to change that out too?

damn mama warbucks.............you want a boyfriend? or another son?

what did he break? an arb? or that crappy d35 rearend?

and yes you could run an aussie in the rear and a arb in the front but i wouldent

any how what axle does he have?

We think his locker did or did not fully engage the last time he used it, this was after he broke his dana 35... all the gears on the locker were in pieces, ARB would not warantee it because it was an older model, so he is not locked on the rear.

I think he put a 44 on the back after his first breakage.

Marshall is working hard (Washtub) I told him to spend all of his money he wants because after he gets married, kids etc, etc its all over.

Renee10 wrote:

Marshall is working hard (Washtub) I told him to spend all of his money he wants because after he gets married, kids etc, etc its all over.

aint that the truth . so far, no kiddos so i still get a little $$ here & there for my hobbies. right now this jeep gots me fully tapped.

i pick hobbies that my kiddos can enjoy too... that way the money is spent on them :mischieviousbi .

hey kids, lookie here!!! daddy got you a D60 Rock Jock setup for christmas! who needs college anyways?!?!

JK-fredd0 wrote:

i pick hobbies that my kiddos can enjoy too... that way the money is spent on them :mischieviousbi .

hey kids, lookie here!!! daddy got you a D60 Rock Jock setup for christmas! who needs college anyways?!?!

Sounds like a good plan! LOL

JK-fredd0 wrote:

i pick hobbies that my kiddos can enjoy too... that way the money is spent on them :mischieviousbi .

hey kids, lookie here!!! daddy got you a D60 Rock Jock setup for christmas! who needs college anyways?!?!

Just don't lose it when they fill it with sand

CRUX wrote:

JK-fredd0 wrote:

i pick hobbies that my kiddos can enjoy too... that way the money is spent on them :mischieviousbi .

hey kids, lookie here!!! daddy got you a D60 Rock Jock setup for christmas! who needs college anyways?!?!

Just don't lose it when they fill it with sand

or get old enough to take it for a "spin"