seems theres a lot of folks on this forum lately asking about lockers and installing them, specifically about the front D30.
recently installed my front Ausso i figured i'd do a quick write up so people can get an idea of what this costs to install etc.
note, i only have a few pics. as far as how it works, it gives me great traction in 4wd, and so far i can't feel it on the street. NOTE; i don't know how it'll handle in the winter and honestly, the jeep will likely not be driven when roads are bad for that specific reason.
anyway, here goes.
2L gear oil
basic mechanics tools impacts are nice.
first step; get the jeep off the ground; take tires/brakes off. pull the shafts. i just pull the shafts/hubs as a complete unit; pull off the diff cover and drain it.
please note, if you can't get to this step, don't install this locker.
now that the covers off and shafts are out, you have to take out the differential/centre section.
remove the carrier bearing bolts and MARK THE POSITION so you put them back in teh exact same position. i marked the cap as well as labelled where i put them.
at this point, the differential needs to be pulled; most manuals will tell you to use a carrier spreader or a crowbar. well if ur jeep sucks like mine, then the carrier will just fall out........ make sure to keep the bearing races with the appropriate caps (they are side specific.
now the carrier is out. good job.
next, pull the roll pin out of the differential cross pin. i used a small screw for this or if you have a small punch that would work. its jsut a simple roll pin. knock it out through the little hole in the carrier.
pins out? now time to unbolt the ring gear. undo all the bolts holding it on; make sure to mark the relation of the ring gear to the carrier so you put it back on correctly. if the ring gear sticks when you pull it off, use the small brass punch to gently pry the ring gear off.
now you can pull the centre cross pin and remove the spider/side gears. make sure you keep the thrust washers to reinstall with the locker.
now the locker itself can be tricky.
install the passenger side first (or drivers, whatever shouldn't matter) apply great liberally to the teeth of the locker; this will help hold everything in place. install the second part (forget technical name)and the special spacer included with it (for non cclip axles) and hope the grease holds it in place. install the other side of the locker, again, adding grease to the teeth to hold it in.
this parts kind of a pain in the butt becuase you will probably drop it at least once. when you have the parts in place, grab one of the little pins and slid it into the locker. (you will see the grooves where it fits) push it and align the two locker parts together. once it clicks into place, put a little spring in to keep the pin locked;
MAKE SURE THE HOLES LINE UP for the crosspin to go back in. this will really piss you off if you don't lol.
once the first pin is in theh other 4 should be simple. just rotate teh whole assembly until you can get access to the next pin.
reinstall the cross pin.
at this point the diffs put back together and ready to reinstall.
put the ring gear back on torquing to 55 ftlbs. use red loctite on the bolts; nothing sucks more then grenading a diff because you forgot. tighten bolts in a star-type pattern. at this point measure the gap as per the instructions with the locker. if its in spec then pop it back in.
now you can reinstall the carrier into the housing. make sure when you slide the carrier in you have the bearing races on the proper sides, and make sure you put it in straight; don't force it. it will go; once its almost in, turn the carrier until it seats itself with the pinion. now you can bolt the bearing caps back up. this was tricky; get one bolt started, then the other to get it seated; start the other side at this time, again, putting them in the SAME way you took it out. once you have all four bolts installed, take one out at a time, apply RED LOCK TITE and then torque em down to 60ftlbs.
this is the tough part. now its done; the rest is just popping axles back in and filling the diff.
note; if you think you need axle seals then do them at this time. i didn't need em so i didn't do em.
all in took me 4 hours, 8 beers, one sandwich, two nagging phone calls from the wife. i sure wasn't going fast because i was rather enjoying my beer. but overall simple install if yo uhave the right tools (like a lift. that helps)
if you have questions fire away