Aussie Locker finally going in

[carlover]

No i didnt have the original instructions and i used a write-up for the 8.8 i found on thier website. i guess im pulling everything back out and starting over again. I dont have any assembly lube, is there anything else i can use????

My computer is tripping and wont download that file...

 

[carlover]

im gonna just pull everything back out and try again. I just dont think it will go in any better a second time.... i have a pic of what it looks like right now.

If the center pin was nothced all the way down it would work, but for some reason its just nothced in certain parts. Im lost....this is irritating.

 

[95exploderboy]

A notched cross shaft isn't necessary for this to work correctly, it seems that something else is wrong. Do you have feeler gauges to check the measurements that Aussie reccomends? I suggest you start over using the pdf and the feeler gauges to make sure everything is in spec. as you are going along.

 

[carlover]

my computer wont download the PDF file for some reason, its on its last leg. And i dont have a feeler gauge, i guess im off to the parts store to get assembly lube and a feeler gauge. Do you happen to have a quick list of the specs listed on that file???

What is the secret to getting this thing back out??? Im having a hell of a time with this install. This should be simple and easy....but then again what ever is just just and easy.

 

[carlover]

Anyone???

 

[DB_1]

I've got my instructions out for the Aussie locker and i'll try and describe the tolerances as best I can.

Have your feeler gauge ready, you're gonna have to stack some of the feelers together to get the measurements you are after.

First measurement is the gap between the pinion shaft and the spacers (the pucks that fit inside the side gears...should be between: .006 and .020

If it is out of tolerance, either the case is worn or the thrust washers are worn. The locker needs to have this gap to operate properly.

The second tolerance is the center gap. This is the gap between the 2 halves when installed. Center gap should be between: .145 and .170

Also, when you take your locker out, check your thrust washers and make sure they aren't warped by laying them on a flat surface...visual inspection.
If they are warped, it could throw off your tolerances.

Good luck

 

[carlover]

Thank you very much. Ill check those measurements in the morning. Getting to those c-clips after everything is together is a PITA. Im still trying to get those off lol. Im hoping to get everything done so i can come to truckhaven next weekend.

Which ones are the thrust washers?? The ones that come off the outer gears on the axle????

 

[zhanx]

carlover whats your axle code on the door?

 

[carlover]

I have open 3.27's in the rear differential. im gonna go back out and try to pull everything back out, those c-clips are a PITA to get to once everyhing is installed. Any ideas what would cause things not line line up right???? Everything is together right, just the clips covers arent seated enough to slide the center pin through.

 

[carlover]

This thing just will not come backout. Its making me look like an idiot lol. Every person i talked to and writeup i read said this was an easy install, just my luck mine has to be impossible.

Anyone have any ideas what could be making the clip covers not seat properly??? They are sitting flush with the axles when they are pulled all the way out. I think the gears that sit on the axles might now be seating right....if i can ever getit back apart ill figure it out i hope.

 

[RockRanger]

If I remember right on the axle shaft there is a rubber o ring in the sae groove as the c clip. Did the clip get put on the wrong side thus not allowing the axle shafts to be pulled out all the way to allow the cross shaft to install. Just a guess though.

 

[carlover]

That could be, if i could get the thing apart id probably figure it out. Once installed it looks as if the c-clips have no space to be taken out again.

Is there anyone local who knows about these things that could please give me a hand. This thing is killing me lol. ive done many things with many different vehicle over the years but this had to be the worst.....

 

[carlover]

anyone have any clue how to get this thing out??? I cant get the cclip on the passenger side axle off, there doesnt seem to be any way to get it back out...

Im gonna call tech support at offroadlockers tommorow and see if they can help but any help you guys could give me would be wonderful. I dont want my ex to sit.

Also will it damage anything if i have to move the truck??? I wont start it but i do need to move it or the wife is gonna have my head when she gets home.

 

[DB_1]

Which ones are the thrust washers?? The ones that come off the outer gears on the axle????

Yes, those are them...hope you saved them

Wish I could help you out more but it's been a long time since i've been inside an 8.8, i'd need it in front of me to see what's going on.

 

[carlover]

yeah i saved them. I put them back on the new gears and checked them before i put them on and they were fine. If i could only get that C-clip off everything else would just fall out. If im looking down the side of the locker that gives access to the clip i can see it clear as day. But there is no area on the other side of the locker locker for the clip to come out. I know none if this makes much sense without pics. When i go back at it tommorow ill get pics so maybe someone can help me out.

 

[carlover]

well im off to try to get this thing out again...If i can just get that damn clip out itll be a good day...

 

[carlover]

Well the locker is back out now.

Rockranger it looks like you were right. The o-rings on the axle were on the outside of the spline which meant the clip wasnt completly against the end of the axle which means the axle wasnt able to be pulled out far enough to allow the c-clip covers to fully seat.

Now the dilema is whether to try again or just to put the stock gears back in and call it a day.....

 

[chrisis]

i would definetly try again now when you have everything open.

as you said you figure out the problem so go for it.

 

[carlover]

ok reinstalled. The c-clip covers are fully seated against the outside gear and there is still not enough space for the center pin to be re-installed. Anyone who has ever done this job, do the clip covers have to be flush in the hole where the center pin goes??? This is getting on my nerves. It is installed right, i have no way to get a feelr gauge so i cant measure things up. But that wont do me any good considering i cant even get everything together anyway.

Sorry if im ranting this is just getting on my nerves....

So my question is are the c-clip covers supposed to sit flush in the hole where the center pin goes?? They only stick out a few millimeters....

 

[carlover]

well this adventure has come to an end. i had a buddy stop by and mess things up completely. i told him to leave it alone but i went inside to use the restroom and he really f'ed things up. i have everything back together again but the center pin wouldnt fit. I had decided to just take everything apart and keep it stock. He decided to use a hammer and pound the center pin in and force it through like a moron. Well he ponded it through all right now the pin is all the way back in the back end of the diff. There is no way to get the pin out now and the whole assembley is frozen. Looks like i have to repace the whole damn axle now. I know there is no way to get that pin out now. I could shoot this guy right now......Well im off to search for a whole new axle.....thanks everyone for thier help.