Torq-Masters Aussie Locker series Installation Manual

INSTALLATION MANUAL

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A S E KSS E C E

AUSS E LOCKERAUSSIE LOCKER

AUSSIE LOCKER

INSTALLATION INSTRUCTIONS FOR SPICER (DANA) MODELS, AMC-

INTRODUCTION

Your new Torq-Masters “Aussie Locker®” will provide you with the maximum in advanced traction per­formance 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. When­ever terrain onditions would normally cause wheel spin to occur, the Auss e Locker automatically trans­fers 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 y our installation to familiarize yourself with
the steps performed for your particular axle type and to determine what tools you might need

STANDARD DIFFERENTIAL OPERATION

2 Allows if ere t al actio bet ee th wo w eel –perm ts hem o r tate at iffe

d ring ornerin to e iminate drive train amage an re uff n

r v ng with no t re slippage ha f (50%) of he n om n en n ower i t ans itted to each wheel or
50 50. n a lippery trac ion itua i n f n heel sp ns with onl 10% f he engine power pl ed t it
the ot er wheel als e eives only % of the po er o 10 0 h s mea s hat the vehicle is tryin to
move wit nly 20% f he o al p w r ap ie to th ound s h t at it may n mo e The eh le is
stuck

rov ding s much as 1 0% of he av lab e p we to e her w eel (100-0 w e he ot er o e s on a
s ick surf ce or ev n ff the r n in a hol , yet i a a l s the whe s ro a e differe t spee s
d ri a turn Th s means that if one wh el s n sol d ground w e cellent tr tio n o e wh el is on
ice and wo ld s p ith 10% of t e p wer a p e t a the n on ol d gr nd w l receive 90% of he
power nd th ot er e w ld receive 0% 90 0 Th 90%- owe wheel will m ve the ehic e st
fine s you w ldn’ even know tha y u d h ve been stu k

l ke tor on bar Power i appl ed o b th axles when he 10% w ee ow t ac i n) be ins to sl p he
axl shaft f r the 90% wh el (goo t a tion wraps up a l t e more as n ne ower i applied he 0%
whe l sl ps a littl more and he 90% a e w aps p a it e m re unt l enough powe i fina ly li d o
m e t e e cle It m m e before al 90% s p lied b hese i l tra ions how the heore i al
maxim m t at may ome into p a A ur v h c e im s u a hil his t rs o bar effe t transfers
power ba k d orth tan ane sly ro sid to side as ne wh e t he other ne s ps li tle and
then egains tr t o Your new Aus e cker thus e fort essl and aut ma i a l g v s yo he most
p w r to the wheel w h th mo t tra t on and you ust keep ri ht o oing Onw rd!

r Pos Traction d ferent als se c utch a ks s ha these di fe nt al ases are not compatible w h
the Au s e Lo er If y h ve imit d- ip differ tia yo l eed t pur hase an eq iva ent pen
d ff rent a ca e i on aft n s e ear thru t ashers an hav t e ase ins a led prior to the
installation of the o ker Set of t e ca e in es s tting the d ff renti l be ring re-load n t e r -
and-pin o ba lash wh ch generally mus be done by a s op ha ing the righ n wle e an o l

wa her u der ea h a e ear It s e at ve t at you t rus was er are not wo n w rped ra ed or
scored and t a th y be of t e or g al h kness I yo r wa hers are wor o da aged p ha e n w
o es They are heap and re good s ra ce If do n t nstall hru t washe s of the proper th ck ess
and oo cond t on the o tact atterns w l ho he d ffere e i h w l o d he w rra y

The standard, or “open” differential provides two functions:

1. Transmits engine power via the drive train to the wheels to move the vehicle; and

2. Allows differential action between the two wheels–permits them to rotate at different speeds

during cornering to eliminate drive train damage and tire scuffing.

The standard differential design always provides equal amounts of power to each wheel Thus, in normal
driving with no tire slippage, half (50%) of the incoming engine power is transmitted to each wheel, or
50-50. In a slippery traction situation, if one wheel spins with only 10% of the engine power applied to it
the other wheel also receives only 10% of the power, or 10-10. This means that the vehicle is trying to
move with only 20% of the total power applied to the ground such that it may not move. The vehicle is
stuck.

Your new Torq-Masters Aussie Locker overcomes the traction deficiencies of the open differential by
providing as much as 100% of the available power to either wheel (100-0) when the other one is on a
slick surface or even off the ground in a hole, yet it also allows the wheels to rotate at different speeds
during a turn This means that if one wheel is on solid ground with excellent traction and one wheel is on
ice and would slip with 10% of the power applied, that the one on solid ground would receive 90% of the
power and the other one would receive 10% (90-10) The 90%-power wheel will move the vehicle just
fine, so you wouldn’t even know that you’d have been stuck.

For you techie types, the reason that this unequal division of power can occur is that the axle shafts act
like torsion bars. Power is applied to both axles; when the 10% wheel (low traction) begins to slip, the
axle shaft for the 90% wheel (good traction) wraps up a little more as engine power is applied. The 10%
wheel slips a little more and the 90% axle wraps up a little more until enough power is finally applied to
move the vehicle It may move before all 90% is applied, but these illustrations show the theoretical
maximums that may come into play. As your vehicle climbs up a hill, this torsion bar effect transfers
power back and forth instantaneously from side to side as one wheel, then the other one, slips a little and
then regains traction. Your new Aussie Locker thus effortlessly and automatically gives you the most
power to the wheel with the most traction, and you just keep right on going. Onward!

PRE-INST ALLATION INFORMATION

The Torq-Masters Aussie Locker is designed to fit into a standard or “open” differential case Limited-slip
or Posi-Traction differentials use clutch packs, such that these differential cases are not compatible with
the Aussie Locker. If you have a limited-slip differential you will need to purchase an equivalent open
differential case, pinion shaft and side gear thrust washers and have the case installed prior to the
installation of the locker Setup of the case includes setting the differential bearing pre-load and the ring­and-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 installed with a factory thrust
washer under each axle gear. It is imperativ e that y our thrust washers are not worn, w arped, cr ack ed or
scored and that they be of the original thickness. If your washers are worn or damaged, purchase new
ones. They are cheap and are good insurance If you do not install thrust washers of the proper thickness
and in good condition, the contact patterns will show the difference which will void the warranty.

USSIE LOCKER P RTS

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Cross shaft (pinion shaft) The Dana 5 models come with a special cross shaft
Thrust block Future models may include a thrust block where required

AUSSIE LOCKER PARTS

The Aussie Locker kit consists of the following parts:
Two cam gears

Two axle gears
Two spacers
Four pins
Four precision springs

Insta lation Manual
Supplemental Installation Information (if applicable)
Operator’s Guide
Sticker

Additional parts for some models:
Cross shaft (pinion shaft)—The Dana 35 models come with a special cross shaft.

Thrust block—Future models may include a thrust block where required.

ADDITIONAL PARTS USED

You will use your existing side gear thrust washers and cross shaft(s), assuming that they are in excellent
condition. These parts must be replaced if your differential is high-mileage or if wear is evident. If you are
also replacing axle shafts as part of this installation and if your differential has a thrust block, check to see
if it needs to be changed or if end-play adjustment is required.

Note: Thrust Blocks: T oy ota Land Cruiser installations do not use the factory thrust block; Jeep AMC -20
differentials do use the thrust block. (If axle shaft end play is involved (AMC-20), the thrust block is required
for correct installation.)

Also note that for all differentials the spider gear thrust washers are NOT used.

Before starting the installation be sure that you have replacement gear oil of the type recommended by
the vehicle manufacturer, and any seals that will need to be replaced. If the vehicle is to be used in hot
weather we recommend the use of 85-140 gear oil, which will provide adequate lubrication and minimize
any sound. Also, synthetics can be used with the Aussie Locker. A dial caliper or a micrometer and set

of feeler gauges are also needed for checking the various existing parts to determine if they
need replacing.

SHOP MANUAL PROCEDURES

As stated above, it is important for you to have your shop manual available and know the R&R proce­dures that apply to your particular vehicle. The Aussie Locker instructions will describe in detail how to
install your new locker, but they will only mention in general terms about how to remove backing plates
(if even necessary for your vehicle), pull out the axle shafts, remove the differential case, etc. It is up to
the installer to determine the proper method for axle housing and differential disassembly , and be able to
remove the pinion shaft from the differential case so that the locker can be installed.

DIFFERENTIAL DESIGNS

These instructions will assume that the installer has already consulted the shop manual and/or the
internet and various club resources and determined what type of differential design is in his vehicle. There
are two types of axle housing designs in which the Aussie Locker is used. These are: (1) Integral carrier,
such as in the Spicer (Dana) line; and (2) Removable carrier (third member), such as in Toyota Land
Cruisers (although in these vehicles the rear carrier generally is not removed from the vehicle). In turn,
these 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 AMC­20 with thrust block); (3) Full-floating axles (Land Cruiser fronts, some rears, early Dodges, etc.). The
Aussie Locker design will operate with all these various types of differentials.

E I I X E DIS SSE BL S E S

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E O O HE DI E E I C C I X ES

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E O O HE DI E E I HI I G GE

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dif r ti l fr m t arri r (A l this d s rib L n r is f on di er ti ls i h
h f ll fl ati l )

PRELIMINARY AXLE DISASSEMBLY STEPS

NOTE: the following steps and paragraphs are suggestions that we provide to help you with the successful
installation of your new Aussie Locker. You are ultimately responsible for the safe installation of your new
locker and the safe operation of your new locker-equipped vehicle.

The following general steps are done prior to removing the rear differential; similar steps are used for the
front unit. They are meant only as a guide to be used in disassembling the axle for your particular vehicle.
Consult your shop manual for the exact steps that are needed.

1. Position the vehicle on level ground and block the front wheels.

2. Loosen the rear lug nuts by 1/2 turn if the tires will need to be removed. Generally, for C-clip axles, the

3. Release the emergency brake and put the transmission and transfer case in neutral.

4. Carefully jack up the rear axle and place it on jack stands.

5. Remove the tires (if needed).

6. Loosen the bolts around the differential cover or the around the third member . Dr ain the gear oil. Remove

7. If you have determined that your vehicle has a C-clip differential, proceed directly to the section below

8. Observe the ring gear to see if it is thin enough so that you can pull out the pinion shaft. If so, proceed to

9. If the ring gear is too thick to be able to pull the pinion shaft out past the teeth, proceed to the section

tires can remain in place.

the cover.
entitled C-Clip Axles.
the section below entitled Thin Ring Gear.
below entitled Thick Ring Gear .

Notes:

1. The pinion shaft is usually retained by a special bolt or by a roll pin or even by a solid pin. In some

2. If you find one thrust washer, there are two (1 per each axle gear). Sometimes they “stick” to the backs

REMOVAL OF THE DIFFERENTIAL—C-CLIP AXLES

The following steps are a general guide to removing the differential assembly from C-clip axles. Consult
your shop manual for the detailed steps required to open up the differential housing to expose the
differential. C-clip axles are the easiest design for differential replacement; in these axles the differential
case remains in the vehicle and the installation of your Aussie Locker is done in the vehicle rather than on
the bench. Note that with only one person, removal of the tires makes 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 three inches.

5. Remove the spider gears and side gears and all thrust washers.

6. Proceed to the section below entitled Examination and Preparation of the Parts.

REMOVAL OF THE DIFFERENTIAL—THIN RING GEAR

If you have determined that the ring gear is thin enough so that the pinion shaft can be removed without
further disassembly, do not remove the differential case from the vehicle. Yo ur new Aussie Locker can be
installed with the differential case remaining in place. If your differential is in a third member with no
removable cover on the axle housing, remove the third member from the vehicle and place it on the
bench. If the ring gear is thin enough, follow instructions 1, 3 and 4 below but do not remove the
differential case from the carrier. (As an example, this describes Land Cruiser front differentials which
have full-floating axles.)

differentials a bearing cap must be removed to enable the bolt or pin to be removed using a small wrench
or a long punch Consult your shop manual for the exact procedure.

of the side gears or to the case and one seems to be missing. Check very carefully.