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Unread 02-09-2013, 09:22 PM   #1
ronjenx
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OEM Rubicon Locker Study

A forum member recently sent me his old Rubicon e-locker.
Here is a quote from the owner:
"...when wheeling in tough areas (sand, mud, rocks &tc.) I put the locker in for a while & then take it out, put the locker in for a while & then take it out, repeat. So, I've used it a lot. My Jeep has 105K miles & I'll bet 15-18K of that is off road."

It has seen some good use. The differential and dog clutch show very little wear.
The ring in the 3rd picture below looks quite worn, leaving a small lip at the inner diameter
That could be the cause of locker ratcheting.
Installing a shim to make up the difference has at least temporarily fixed it in some cases.




Here is a look at how the Rubicon e-locker works.




























See this great video to review how a regular differential works:


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Unread 02-09-2013, 10:29 PM   #2
durable1
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Great pictures. Very interesting post.
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Unread 02-10-2013, 05:36 AM   #3
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Well done Sir. You are a valuable asset to this forum.
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Unread 02-11-2013, 10:05 AM   #4
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Wahoo! That answers several of my locker questions. Now, this is a technical thread.
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Unread 02-11-2013, 02:54 PM   #5
MoreMud
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One of the best explanations of a locking differential I've seen, thanks for putting it together.
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Unread 03-17-2015, 04:09 AM   #6
S_Bartfast
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Firstly I want to congratulate you on a most excellent post. I've search long and hard for details on the Rubicon Locker and I must say you've done an exceptional write up here.


One question though....
Are you able to explain how it is the spider gears themselves rotate?

The reason I ask is that my front diff started making a horrible noise whenever I turn sharply while 4WD is engaged. I took it to the workshop and they pulled everything apart and found a nice shiney little bonus bit in my locker:

The first thing I thought was that it looked like the needle bearing in a uni cap and I started to wonder where the bearings that the spider gears roll on are. Would it be possible that this part is from one of the spider bearings?

In any event my diff has clearly experienced some serious violence and is in need of a complete rebuild. This is what one of the pins that go through the end of the spider shafts looks like:
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Unread 03-17-2015, 07:34 AM   #7
MrSundays
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This is amazing. Thank you. A buddy of mine and I had a debate if it was an e-locker or a low compression clutch. Thanks for the clarification and explanation.

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Unread 03-17-2015, 07:50 AM   #8
Moezer
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So what would break this locker while off roading? and what will break when it does break the edged dog teeth or the pins

The way its set up its kinda like the spartan locker design
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Unread 03-17-2015, 08:08 AM   #9
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Book of knowledge-


Quote:
Originally Posted by ronjenx View Post
A forum member recently sent me his old Rubicon e-locker.
Here is a quote from the owner:
"...when wheeling in tough areas (sand, mud, rocks &tc.) I put the locker in for a while & then take it out, put the locker in for a while & then take it out, repeat. So, I've used it a lot. My Jeep has 105K miles & I'll bet 15-18K of that is off road."

It has seen some good use. The differential and dog clutch show very little wear.
The ring in the 3rd picture below looks quite worn, leaving a small lip at the inner diameter
That could be the cause of locker ratcheting.
Installing a shim to make up the difference has at least temporarily fixed it in some cases.




Here is a look at how the Rubicon e-locker works.




























See this great video to review how a regular differential works: http://www.youtube.com/watch?v=K4JhruinbWc
If I didn't thank you before RJ, thanks again

Quote:
Originally Posted by S_Bartfast View Post
Firstly I want to congratulate you on a most excellent post. I've search long and hard for details on the Rubicon Locker and I must say you've done an exceptional write up here.


One question though....
Are you able to explain how it is the spider gears themselves rotate?

The reason I ask is that my front diff started making a horrible noise whenever I turn sharply while 4WD is engaged. I took it to the workshop and they pulled everything apart and found a nice shiney little bonus bit in my locker:

The first thing I thought was that it looked like the needle bearing in a uni cap and I started to wonder where the bearings that the spider gears roll on are. Would it be possible that this part is from one of the spider bearings?

In any event my diff has clearly experienced some serious violence and is in need of a complete rebuild. This is what one of the pins that go through the end of the spider shafts looks like:
More great info-thnks SB-

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Unread 03-17-2015, 08:14 AM   #10
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This is a cool thread....the operation is very well-explained for those that require good visuals. I recently built a pair of JKR44's with ARB's and have the factory lockers set aside collecting dust. They were in a fire so not everything is in perfect condition but they'd likely make for great spare parts doners. If any of you guys have interest in them feel free to PM me.

If this is against the rules, go ahead and delete it. But considering the extreme niche market of these parts I'd appreciate the exposure since I have no use for them but others most certainly do.
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Unread 03-17-2015, 08:50 AM   #11
ronjenx
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S_Bartfast ,

The spider gears have no "bearings". They rotate on the shafts that go through them, and are pushed out on cupped and polished, hardened washers. There is enough oil on everything to handle the wear.


When you get the noise while turning sharply in 4wd, is it with the locker engaged?
What kind of noise is it, and what is the steering wheel doing during this.
Also, how much traction do you have at the time?
Did the pin you found cause damage to other parts?

I can't think of anything in the diff that would have small needle bearings. I'll take a close look at mine and see if there is a small pin that could fall out.

Do a search for the word Study in the title to find more threads like this one.
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Unread 03-18-2015, 03:45 AM   #12
S_Bartfast
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Quote:
Originally Posted by ronjenx View Post
When you get the noise while turning sharply in 4wd, is it with the locker engaged?
Just in regular 4WD, nothing locked.

Quote:
Originally Posted by ronjenx View Post
What kind of noise is it, and what is the steering wheel doing during this.
Also, how much traction do you have at the time?
Aside from the noise everything else is fine. Steers fine, traction's fine. It actually worked perfectly, just sounded awful!

Here's a short video demonstrating the sound before it was disassembled:
I'm in Australia and we drive on the "Queen's Side" here
(And yes, I know you should never engage 4WD on bitumen)


Quote:
Originally Posted by ronjenx View Post
Did the pin you found cause damage to other parts?
It was actually my mechanic who found it (I'm no mechanic myself, just an interested geek) and the second picture is the only part he showed me specifically. I believe the second pic is a "cross pin retainer". I saw the other parts and they kind of looked fine to me but I wouldn't really know. My mechanic didn't mention anything about them specifically but said the "bonus" bit must have gone through the gears at some stage and caused the damage to the second part. If you look closely you can see the pin is both scuffed and bent, and it you look really closely you can actually see that the "bonus" bit is also slightly bent.

Here are links to the full resolution images:
Pin (2.7MB)
BonusBit (2.8MB)
(let me know if you can't download the full res images)


Quote:
Originally Posted by ronjenx View Post
I can't think of anything in the diff that would have small needle bearings. I'll take a close look at mine and see if there is a small pin that could fall out.
No, nor could my mechanic

Quote:
Originally Posted by ronjenx View Post
Do a search for the word Study in the title to find more threads like this one.
Will do.
I think I came across your "Totally Integrated Power Module" thread before. That was a really good piece of work to.
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