WJ Dana 35 Aussie Locker Install...
So I installed my Aussie Locker this weekend into the WJ. I was short of some necessary tools that would have "eased" the time of the job. I'll post in order what I did; no pics for this (sorry) but it's really not necessary since it's quite simple.
Slide Hammer (makes pulling the shafts so much easier)
Vice Grips (in case your axle is the stud/nut assembly and one is loose)
1/2" Drive Ratchet
3/8" Drive Ratchet
Socket set (obviously)
1/4" Wrench or 1/4" 12pt. socket
Files, good new files or a die-grinder
Screw driver set
(You're going to want the vehicle in NEUTRAL for this install)
1. Remove tires.
2. Open differential cover and let gear oil drain.
3. Remove caliper slides (hex wrench) and hang caliper with wire out of the way.
4. Remove caliper bracket (2 18mm bolts I believe).
5. Remove Rotor.
6. Remove 4 nuts (14mm or 15mm) for axle shaft.
7. Repeat steps 3-6 for other side.
8. Spin your drive shaft to expose the differential cross shaft set screw. This is the 1/4" 12pt screw that holds the cross/pinion shaft in.
9. Once the cross shaft is removed spin the drive shaft to access the spider gears for removal. Keep track of your left and right spider gears in case a spacer comes out with them.
10. Once the spider gears are removed (most likely will fall out easily) pull each axle shaft out 6"-8" using the slide hammer or your rotor (reversed). Mine took some heavy pulling to remove.
11. Spray some brake cleaner and clean out everything you can.
12. Assemble one side of the Aussie Locker using bearing grease to keep the assembly together. Place the axle gear, cam gear and spacer into one side of the differential housing.
13. Place bearing grease on the other axle gear for the cam gear. Place the axle gear (only) into the other side of the differential.
14. (This is where it starts to suck) Test fit your last cam gear/spacer for carrier fitment. Notice that the locker can not go in with the flat sides top/bottom but rather the rounded edge must be installed to allow axle gear fitment (you'll notice the notch in the cam gear on the axle gear side). If it doesn't fit you'll need to file the carrier down top and bottom.
15. Keep filing (this is where the grinder comes in hand)!
16. Test fitment again. (I hammered my cam gear/spacer in with a rubber mallet). Once both axle gears, cam gears and spacers are properly installed it's time to install the 4 pins and precision springs (self explanatory).
17. Finally, install the cross shaft and bolt it back into the carrier.
18. Use feeler gauges to make sure you have proper clearance between the cross shaft and the cam gear.
19. Reassemble everything and fill her up with gear oil (I was unable to test it as Aussie specifies).
I was nervous about tackling this at first. Once I got it all started and into it though it all came together. Just be prepared for any kind of issues (for instance carrier fitment issues). Due to not having a grinder I spent a good 3-4 hours filing my carrier because I didn't realize how much would need filed down. If I didn't run into the filing by hand issue or the studs broken loose on the axle shaft assembly I would have been done in roughly 3 hours tops.
I hope I covered everything and this is a little heads up for SPECIFICALLY the WJ Dana 35 (since there are many differences in Dana 35 carriers).
2014 JKU Rubicon *DAILY DRIVER*
Gone but not forgotten; 2005 LJ *SOLD* 1987 XJ *SOLD* 2002 WJ *SOLD* 1995 ZJ *SOLD*