How to install a lunch box locker

There are several brands of what we call lunchbox lockers. These are locking mechanisms that replace the spider gears in a standard differential carrier. Here is a pic of the Aussie Locker brand

http://i649.photobucket.com/albums/u...ps5605ad07.jpg

Installation of the locker itself will be the same in any standard carrier in the front or rear axel assembly.

The first step is to jack up the axle and support it with jack stands. Here is an example of how to remove the axle shafts for a D35 rear axle
The only addition to this procedure would be the removal of the C clips holding the axle shaft in if you have them. This axle did not. However if that is the case, remove the differential cover and remove the C clips before doing the following

http://i649.photobucket.com/albums/u...f/IMG_1109.jpg

To start, jack up the rear, remove the wheel and brake drum. It should just slide off.

http://i649.photobucket.com/albums/u...f/IMG_1110.jpg

Next, there is a small plate with four bolts on it that holds the axle in. These must be removed next. It is not necessary to remove any part of the brake assembly.

http://i649.photobucket.com/albums/u...f/IMG_1111.jpg

If you have ever wanted an excuse to get one of those flexible ratchet wrenches, this is the time

http://i649.photobucket.com/albums/u...f/IMG_1112.jpg

The plate should slide freely off the studs like this.

http://i649.photobucket.com/albums/u...f/IMG_1113.jpg

http://i649.photobucket.com/albums/u...f/IMG_1114.jpg

Next, the axle should be able to be removed. However if you have C clip axles, you will have to remove the differential cover and rotate the carrier to the appropriate position and remove the C clip first. To remove the axle, you will need a slide hammer. These can be rented or borrowed from many parts stores.

If you are installing a lokka in the front axle, the procedure is a little different. First jack up and support the front axle. Remove tires.

http://i649.photobucket.com/albums/u...ps1aa1097a.jpg

If you have a central axle disconnect (CAD) it is now time to remove the differential cover. It is hard to see in this pic, but there is a snap ring on the passenger side only. You must remove the snap ring before you can get the passenger side axle out.

http://i649.photobucket.com/albums/u...ps0d5124c7.jpg

Removing the axle shafts can have varying amounts of difficulty. First remove the brake caliper using a 13mm socket to remove the two bolts that hold it on

http://i649.photobucket.com/albums/u...ps1318cb46.jpg

Then using a 13mm socket again remove the three bolts holding the unit bearing in the steering knuckle

http://i649.photobucket.com/albums/u...ps52b72d78.jpg

If you are lucky, it will all fall out without any problem.

http://i649.photobucket.com/albums/u...psb2081107.jpg

However it doesn't always happen that way. So next using needle nose pliers remove the cotter pin and lock nut on the end of the axle shaft. Pull the disc off the studs. Then using a 36mm or 1 7/16" socket remove the nut holding the axle in the unit bearing.

http://i649.photobucket.com/albums/u...ps2ec6e049.jpg

Then smack it with a good sized hammer on the back side and work it loose.

If you have a CAD, the next step is to disassemble it. Remove the four bolts holding it on with a 7/16" wrench.

http://i649.photobucket.com/albums/u...ps8cdc8708.jpg

Inside there is a slider ring. Move it to the right and give it a twist and work it out.

http://i649.photobucket.com/albums/u...ps431b2aa5.jpg

Since you have already removed the snap ring in the differential, you can work the inner axle to the side or use a long magnet inserted through the end of the axle tube to slide the axle out a few inches. Do not remove it entirely.

Using a 5/8" socket remove the bolts in the bearing caps on the right and left of the carrier.

http://i649.photobucket.com/albums/u...psffeef818.jpg

After removing the bolts, make sure you keep track of which side the caps came off of and which side is up. This is important. These things are machined in place when manufactured and will have small differences. Also keep track of which side the carrier bearing races came off of. They will have some wear and need to matched to the bearing they came from. I lay them out on a clean surface so that I can in one smooth motion pick them up and have them in the right position and side.

http://i649.photobucket.com/albums/u...ps8bb75e23.jpg

Pry the carrier out and then take it to a bench where you can work with it.

Nice write up Steve. Very well pictured too. Thanks

Nice writeup Steve... I am looking forward to getting a locker once I get my DW issues taken care of... I'll take care of that tie rod you got there... LOL

Now it is time to put the locker parts into the carrier. This is most easily done on a bench. First locate the roll pin that holds the cross shaft in place.

http://i649.photobucket.com/albums/u...ps4854bfc2.jpg

Next turn the carrier over and locate the same hole in the back side

http://i649.photobucket.com/albums/u...psc2c8065f.jpg

Then using a 3/16" pin punch drive the roll pin out

http://i649.photobucket.com/albums/u...ps6a1c447d.jpg

If the cross shaft will come out without hitting the ring gear, then gently drive it out. (Many people try to grind off parts of the shaft or parts of the teeth of the ring gear to avoid taking it off. Do not do this. It just makes weak spots and may cause the pinion gear to loos a tooth or cross shaft to break) If not, mark the position of the ring gear and then remove the bolts holding it on. Then gently tap the gear and it will come off. Then rotate the spider gears and thrust washers out

http://i649.photobucket.com/albums/u...ps92a2113f.jpg

Now the side gears can be removed. Remove the thrust washers with them. Many people call these shims, but they are not. They are there to assist in lubrication and are needed for the lokka to work correctly. Put the thrust washer on the lokka side gear.

http://i649.photobucket.com/albums/u...psfdf8025a.jpg

Then insert side gear and washer into the carrier.

http://i649.photobucket.com/albums/u...ps5eaf8a35.jpg

Next take the lokka spacer and put it in the inner halves with the large flat side facing as shown

http://i649.photobucket.com/albums/u...psac2ed566.jpg

Then with the flat sides facing the metal of the carrier, insert them and then rotate them 90° and line up with the teeth of the side gears as shown

http://i649.photobucket.com/albums/u...ps179b7199.jpg

The next step can be done before or after the cross pin is inserted. It works both ways. But I think it is a little easier to do the next steps first.

There are four little pins that come in a little plastic bag.

http://i649.photobucket.com/albums/u...psdfff7172.jpg

Insert them into the slot with the nubs facing away from the hole in the other half. Then push the pin into the other half.

http://i649.photobucket.com/albums/u...pscf312a53.jpg

The next step is kind of awkward and take two hands so no pics of this in action. There are four little springs included also. Do this carefully or these little springs will rocket into some lunar orbit and you will never see them again. They are critical to proper function so don't leave one out because you lost it. Place one end of the spring in the slot and over the nub of the pin you just inserted. Then place a small flat screwdriver into the last coil that is out of the slot. Then put your finger over the spring and don't remove it until the spring is seated. Then with the screwdriver compress the spring until you can push it into the slot and get the spring seated on the nub in the end of the slot. Then you can let go. If you don't have it seated properly, then don' let go. It will look like this when done.

http://i649.photobucket.com/albums/u...n/IMG_1660.jpg

Then insert the cross pin and drive the roll pin in place. Replace ring gear and torque to about 50# Replace the carrier in the housing and end caps and bolts and torque to about 80#. Then put it all back together and oil it up. Happy wheeling

:thumbsup:

Steve,

Great write-up! :thumbsup:

Hoping my PowerTrax will arrive soon....

Like the pics and writeup.