aussie locked 8.8 going BOOM

wishihad1 · Aug 22, 2009

hey everybody

got a friend with an 8.8 and an aussie locker. a few months after we installed the locker it started popping. it does it when turning, and usually under load, but it doesn't matter if hes hard on it or just cruising. it almost feels like the lockers slipping teeth, and then catching, and its gotten to where it does it now 5-6 times in a row and feels like its just going to blow up.

we pulled the locker out and everything looked good. teeth weren't worn, and side shims were on correct. they sent us new springs, but their tech didn't think that would help the problem and i would hate to pull it out and do all that work for nothing

and yes, its installed right, weve probably done 7-8 with no problems

tbburg · Aug 22, 2009

When you say the side shims are on correct, do you mean you didn't forget to put them back in, or do you mean you gauged the distance between the cam gears and the pinion shaft.
From the aussie install manual:

...,
2. Place a thrust washer on each axle gear.
3. Install both axle gears in the differential case.
4. Place a spacer onto each axle gear, with the 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 screwdriver, 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.
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,...

The "improper operation" they're referring to is a skipping and banging like you're describing.

aussie locked 8.8 going BOOM

wishihad1

NAXJA Forum User

tbburg

NAXJA Forum User

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