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INSTALLATION MANUAL

 

 

   

 

 

 

 

 

INTRODUCTION

Your new Torq-Masters “Aussie Locker®” will provide you with the maximum in advanced traction per-

formance available. The Aussie Locker is an Automatic Precision Locking D fferential—it does not require a

switch or external electr c or air control lines to activate nor does it contain frictio  clutch packs. When-

ever terrain  onditions would normally cause wheel spin to occur, the Auss e Locker automatically trans-

fers up to 100% of the available torque to the wheel with the most traction  The result is a dramatic

increase in the performance capabil ties of your vehicle. This is why the Aussie Locker is called the

“Traction To Go Anywhere” advanced traction enhancement system. A 4WD vehicle fitted with one

Aussie Locker will, in general terms, have more than twice its original off-road capability. A 4WD vehicle

with lockers in both front and rear differentials will hav  truly amazing traction, enabling it to travel over

seemingly impossible terrain with less effort that ever before

Installation of your new locker is accomplished by removing the differential gears from the differential

case and installing the Aussie Locker  omponents in their pla e. This typ  of installat on can be made by

the weekend mechanic who is familiar with the operation of a differential and who is able to exercise

appropriate care during the installation process. Normal installation takes about two to three hours when

these instructions are followed. They also assume that the installer has a shop manual covering his

vehicle and that he  s familiar with th  procedures used in removing wheels, axle shafts, etc  Short uts

should not be attempted unless the installer is very familiar with the shop manual procedures for his

vehicle.

Great care has been taken in developing these instructions for the proper installation of the Aussie

Locker; however, the final results are the resp nsibility of the installer. After the l cker is ins alled, the

safe operation of the vehicle is the responsibility of the driver—anyone who drives it should read the

Operator’s Guide for additional information on how to safely operate your new locker-equipped vehicle.

We suggest that you read these instructions before beginning your installation to familiarize yourself with

the steps performed for your particular axle type and to determine what tools you might need

U

E  OCK

AUSSIE LOC

A SSIE LOCK

AUS E LOCK

AUSSIE LOCK

 

   

 

 

FOR C CL P AND NON-C-CLIP AXLES

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AUSS E LOCKER

AUSSIE LOCKER

AUSSIE LOCKER

INSTALLATION INSTRUCTIONS FOR SPICER (DANA) MODELS, AMC-

 

   

You  new  r Mas er  “Auss e L ker®” w ll provi e  ou w th  he max mu  in a a ced tract

formance available.  he Aussie  ocker i  an Automat c Preci i n Loc ing  iff rential—it d es not 

swi ch or exte na el ctric or a r con rol lin s to ac ivate  or does it contain fr ction clutch pack

ever t rrai  c nd t ons would norm lly  ause  heel s in to o c r  the 

ssi  Lock r au omatical

er up to 100% of  he avail ble t que  o  he w eel wi h th most trac on. Th resu t i a d

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he pe or ance  apabili

s of your veh le  Th  i  why the Au s e Locker  s ca

Tractio

o Go Anywhere  adv nced tract on e hanceme  s stem. A 4WD veh cle  itted w

Aussie Locker wi l, in gen ral terms, have more tha  twice its original  f road capability  A 4WD 

w h lockers  n bot

ro t and rear d ffer n ial wi l ha

Instal atio  of your new loc er is accomp ished  y remov n  the di ferential gears from the dif

case and  stal n t e Aussie  ocke

ompone s  n the r p ace.  h s t

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the wee en mechanic wh

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appropr a e care d r n

he in al a ion process.  ormal  nstal atio t kes 

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these ins ruc ions ar  foll we . They als  ass me tha  the insta l r ha  a sh

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Grea care has b en tak n  n d velopin the e  nst uctions  or th proper  nstallation o th

ocke

howe er he fi al resu ts are  he re pons b l t

f the  n taller. Afte t e lock r is i sta

a e ope at on of  he  e icle is the r spo i ilit o the dri er—anyone wh drives it sh uld 

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es ha  you read  hese inst ct ons b fore be nnin  your inst l at

 t  familia

Summary of Contents for Aussie Locker series

Page 1: ...ocker equipped vehicle We suggest that you read these instructions before beginning your installation to familiarize yourself with the steps performed for your particular axle type and to determine wh...

Page 2: ...bearing pre load and the ring and pinion backlash which generally must be done by a shop having the right knowledge and tools As with most factory differentials the Aussie Locker is designed to be in...

Page 3: ...e two types of axles have several differential designs including 1 C Clip axle shaft retention Ford 8 8 Spicer 35 Land Cruiser with thrust block etc 2 Bearing retainer axle shaft retention Jeep AMC 20...

Page 4: ...es sliding the axle shafts in and out easier 1 Remove the pinon shaft 2 Remove the thrust block if present 3 Push the axle shafts inward and remove the C clips 4 Pull each axle shaft out by about thre...

Page 5: ...rta t t put h se hims ba k in h s m l at n nd rd u n r ssembly 5 Ma k the diff r nti l b ring ut r r s s th s is ming ut s th t th n b r inst ll d n th id s 6 M rk t ng ge t s l ati R m th in g r fr m...

Page 6: ...e Aussie Locker axle gears to the back surface and around the hub in the center Using this grease will help with holding the parts in place later on 2 Place a thrust washer on each axle ge r 3 Install...

Page 7: ...stall the C clip on the end of the axle shaft with the points facing downward 3 Pull snap the axle shaft outward to seat the C clip onto the hub of the axle gear 4 Carefully insert one of the cam gear...

Page 8: ...ching the t cam gear with a g etwee the gh han teet Remov the too ver t ng shou d just s there he d n p asse b y may n e to be he d in p ace during the o owing steps W h the e t ax e s owly otate the...

Page 9: ...into the bottom of the slot and the other end should snap over the step on the end of the pin 8 Repeat step 7 for the remaining three pins and springs The assembly of the locker itself is now complete...

Page 10: ...o k m INST LL THE DIFFERENTI L C SE REMO BLE C RRIER THIRD MEMBER j h r r n m s b n r m r T r M m f n f h n n r sh m n f r h r r s h f n n h Th ff n r n th r h s n r n r ss h m r j te s n h h s th e s...

Page 11: ...ke turns slowly at first Remember that if you power around a turn that the inside powered wheel will spin up more easily than before because weight s transferring off it as the vehicle leans outward 3...

Page 12: ...some Toyota differentials it may be necessary to file down casting flashing and case irregularities prior to fitting parts 3 Some Ford Dana 44 front installations may require minor grinding in the ca...

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