How to install a lunch box locker

[4.3LXJ]

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.



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



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



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



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.



Then insert side gear and washer into the carrier.



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



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



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.



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.



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.



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

[Dredwolf]

Steve,

Great write-up!

Hoping my PowerTrax will arrive soon....