Running into problems getting a front lunch box locker figured out | Ford Explorer Forums - Serious Explorations

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Running into problems getting a front lunch box locker figured out

TrackAire

Member
Joined
February 16, 2020
Messages
47
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City, State
Vacaville, California
Year, Model & Trim Level
1989 Bronco II
I'm trying to get a front lunchbox locker installed in my 1993 TTB Dana 35. I thought I had it figured out and bought a Spartan Locker with the 1.5 bore, 27 spline, etc.
But it appears that the 1993 and earlier trucks have a 1.625 bore?? Somehow I missed that and when I talked to USA Standard gear last year, they assured me I was getting the correct unit. Must be Covid fog. lol.

At this point the truck is apart and I'm just trying to get any lunch box locker in there to button this thing up. Does anybody have a part number that will work from either Aussie Locker, Lockrite, etc? And is there anything that needs to be done to make it work? I noticed the Aussie Locker has an additional instruction page on the Dana 35 TTB on how to get rid of the C-clip with a spring. Does this mean the Aussie locker won't work if the c-clip is left in place? This is the supplemental instruction I'm referring to:

I've searched and searched the forum but I'm still not clear on what it will take to get a lunchbox locker installed into the Dana 35 TTB. Any detailed help would be appreciated.
 



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There is a little info in this thread:

What you DO need to know is that there are two different carrier sizes for the Dana 35 - and they are not dependent on Jeep/Ford differences - both sizes show up on Jeeps, one on Fords. The difference is in the size of the spider gears inside the carrier. One is larger in overall diameter with a smaller trunion (the part that inserts into the sides of the carrier - and which drives the axles) while the other are smaller in overall diamerter with larger trunions. They are not interchangable. You need the right size no matter what - gears or quick lock, etc., but otherwise, carriers are interchangable as are the parts inside the carriers.

So, that means that you can run the proper Jeep Dana 35 stuff inside the front TTB Dana 35 axle.


"And you can retain the c clip with only a minimal amount of milling/grinding no need for a spring"

One more...

 






Thanks Rick...I think where I'm running into problems is the bore size of 1.5 vs 1.625. It appears that 1993 and older Dana 35 TTB's are 1.625 bore size. Is this what you mean by the size of the spider gears inside the carrier?
 






Thanks Rick...I think where I'm running into problems is the bore size of 1.5 vs 1.625. It appears that 1993 and older Dana 35 TTB's are 1.625 bore size. Is this what you mean by the size of the spider gears inside the carrier?

I'm not positive, but when I think of bore size for the rear end I think of where the carrier bearings attach to the housing. :dunno:
 






Just got a return phone call from Aussie Locker and email confirmation on the side carrier sizes of the cut off years of 1993 and below for the 1.6 hub bore....And apparently you do have to remove the c-clip and use the spring mod for tension, at least according to Cora at Aussie Locker.
 






Just as a further update to the info I've found. I called Randy's Worldwide which also appears to be Yukon Gear, Spartan Locker, etc.

I finally found a tech specialist that new his stuff....Gus Pyeatt is his name, extension 5599.

Although there are differences in the Jeep Dana 35 regarding side hub size, the Explorer and Ranger platforms with TTB Dana 35s are all the 1.6 variant. I ordered the correct Spartan locker and it should be here early next week. I also found and ordered one of the Echo trimmer springs and it should be here today or Monday. Getting closer to finishing this thing.
 






I just did this on my 94 X back in March.
It is 1.625 on mine. I used the Aussie # 13527.
Here are some pics.
0322211627.jpg
0322211433.jpg
0323211014.jpg
0322211626c.jpg
 






I was able to install it without removing the carrier. But it was a pain to install the springs.
I did do the C clip eliminator mod. I highly recommend doing it and it was easy, and replace the axle seals while you have it out.
 






Thanks A Scott...that is the same thing we're finding.
 






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