8.8 Aussie locker out of spec, thrust washers | Ford Explorer Forums - Serious Explorations

  • Register Today It's free!

8.8 Aussie locker out of spec, thrust washers

damarble

Well-Known Member
Joined
June 20, 2008
Messages
759
Reaction score
56
City, State
Washington
Year, Model & Trim Level
21 Bronco & 88 Bronco II
Need some help here guys. When an Aussie locker is installed, there needs to be .145" to .170" of space between the two halves. Mine measures .140" and my thrust washers are 0.031". To get in spec I need thrust washers at .028" thickness. Can't seem to find them anywhere. Any suggestions?
 



Join the Elite Explorers for $20 each year.
Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!
.











I think the f'ed up their measurements when they built it. My first rear aussie was tight like that also, had to install without the washers (too wide for spec) because NO ONE had them, and no different thicknesses. It failed after a while. Too loose, allowed it to slip a few times and chewed up the gears. I got a new one, same thing, too tight. Aussie acted like I was an idiot but found tons of people with the same problem. I got the center pin in there with a hammer, forgot the measurements but it's tighter than spec. Works perfect. Just put it in that way. Tell aussie they need to re-measure some axles and get it right.
 






I dont think its a problem of specification, I think its a problem of manufacturing.

See I had that same problem on my D44 -- the space between the two halves was just a bit too narrow compared to the specifications stated in the Aussie manual. What did this do to my axle? Well lets take a step back and think that the Aussie, like most lunchbox locker, is a glorified "limited slip" -- allowing one side to "slip" faster or slower than the other say during a slow turn when driving around town. Well when the locker slips is determined by the tension on the springs which is related to how far the two halves of the locker are separated. So when the spring has a lot of force, it is harder for one wheel to slip faster or slower than the other -- which was of course the case in my D44. All in all, this lead to broken axle shafts because the locker was supposed to slip, but it didnt.

So I think the specs in the manual is correct, but at least one part has been manufactured too "thick", which means the specs can not be met.

Is this a concern for the Ford 8.8? Well from what we've seen on the forum with other lockers, 36+ inch tires, but stock axle shafts, the obvious answer is no. But just be aware that when the rear tires start hopping on a rock climb, back off a bit.
 






At least I'm not the only one. Thing is, I have already ran it at the tighter spec for a while and it worked fine at first. Now it "winds up" constantly, even just going straight down the road, and worse on left turns but not right. I'll get a BANG, jerk, BANG, jerk, BANG, jerk, about two per minute. There was some slight damage to the teeth before I put it in (little wear and chipping on one edge, happened while it was in my F150, ran in spec :rolleyes: ) but like I said worked fine for a couple months in the X.
 






If its ratcheting even when going straight, then there's something wrong -- probably one tire is a smaller overall diameter than the other (lower pressure, more worn out, etc..). Try swapping em out for the front tires and see if there is any change.
 






I wonder why it just started though? It's been fine up until about a week ago, then occasionally banged, progressively worse till I stopped driving it on Sunday. Same tires this whole time with the same pressure. It's confusing. I found a bent housing can lead to this behavior as well I checked it and it's fine. (sighted down the empty housing and used a pipe)
 






Well I said screw it and put it back together. Still have that .140 gap. I reversed the cams so the worn edge is trailing. So far so good.
 






Sorry to bring up an old thread, but anyone considering the Aussie should think otherwise.

I had this too tight tolerance too. I called Aussie and they told me too tight is fine, just don't use the thrust washers. I was like, but you guys make such a big deal about using brand new thrust washers in your instructions, are you sure? yes. I didn't listen to him.

So I get the ratcheting in a straight line. I finally turned it in for warranty, the teeth were chewed up. I told them the story and they denied anyone working for them would dare tell me not to use thrust washers. They sent it out to their special analyzer to determine if the problem was my fault or theirs. I was getting nervous because it's such an expensive unit and what if they say it's my fault. Turns out their specialist is the guy who invented the Powertrax unit.

So the specialist comes back with his report, doesn't blame either side, but diagnoses the cause as a too soft cross-pin, which is common in the Ford 8.8. Aussie interpreted this as my problem and didn't cover the warranty. I was irate and sent an email back. I told them it's their problem, their specialist was obvious well aware of this issue, and further, the Powertrax locker for the Ford 8.8 comes with a hardened cross shaft, so this problem is known in the industry. So I fork out almost $400 with no mention of cross-shaft issues and Aussie is telling me, sorry.

They ended up replacing the unit for a brand new one with a reset warrant (refused to give me my money back), but Aussie's last words were that they still shouldn't be responsible. I saved all the correspondence for proof.

So I've got a $300+ locker sitting in my garage, so I figure I might as well try again, this time I'm going to use Powertrax $24 hardened cross-shaft. So I came across this thread because it pissed me off knowing Aussie was receiving complaints at least a year ago and played dumb with me like I was the first.
 






so whats a better true locker?im about to buy the aussie and now im thinking twice
 






I've never used an Aussie, but I've installed quite a few Powertrax lunchbox lockers and never had a problem with one.
 






The Detroit full carier locker.
Posted via Mobile Device
 






is the powertrax a true locker?or would it be just as good to do add a extra clutch?
 






Search for powertrax, we've discussed this many times.
Posted via Mobile Device
 






the Detroit is around $600 that is way to much for a locker,is aussie still having these problems?
 






...Here is a link for current rear lockers discussion...
http://www.explorerforum.com/forums/showthread.php?t=256802&highlight=locker

...Some people have had problems setting up their lockers and Aussie shouldn't be singled out in my opinion...Aussie is one of the only companies who actually has specs for setting up their lockers and attention to get it within specs should be done first..

...The cross pin has also been discussed on several install threads here

.Aussie install instructions...
http://www.offroadlockers.com/install.php/TM744f92/748d/.html

...Here are some past links to info on the subject.
http://www.explorerforum.com/forums/showthread.php?t=145274&highlight=Aussie

...Read this thread but also pay attention to post #20...
http://www.explorerforum.com/forums/showthread.php?t=136355&highlight=Aussie

..Sme of the people with Aussies on this Forum...
http://www.explorerforum.com/forums/showthread.php?t=222133&highlight=Aussie

..Some info on the cross pin...;)
http://www.explorerforum.com/forums/showthread.php?t=235263&highlight=Aussie

..I hope this helps as this Forum is packed with useful information on just about all subjects...:biggthump

...Aussie locker is a member here and yes, I have an Aussie in my X...
 






so whats a better true locker?im about to buy the aussie and now im thinking twice

The Powertrax No Skip isthe best lunchbox I've seen so far. They run about $400 last I checked. I'm happy with the Lockright in the front, virtually identical to the Aussie, I've had the two side by side and the parts interchange. It's about $250+ and seems to be properly made though. I haven't used one in a 8.8 though.

I believe the crossshaft thing to a degree, mine was worn so bad after I pulled the Aussie I had to put a new one in when I went back to spiders.

I'm going to suck it up and use a Detroit in the rear and selectable in the front on my next set of axles. A guy a know is partnered with Yukon testing their Zip Locker and it looks promising so far.
 






is it the front or rear that people are having the trouble with?
 






I had this gap issue a long time ago, I think it was around... 2005, somewhere around there. I talked with the aussie locker guy and took a LOT of measurements because my gap was too tight. What ended up happening was that he told me to get both thrust washers surface ground to bring it into spec, they reimbursed me for the measuring tools I had to purchase, the machine work, and like 100 bucks extra for my time. My locker isn't acting up and locks up when I need it. For 200 bucks(it was how much I bought mine for) it's a great deal... kind of a midway point before you actually decide what you truly want to do with your vehicle.
 



Join the Elite Explorers for $20 each year.
Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!
.





Well atleast they took care of you,but was the problem with the rear or front or both?
 






Back
Top