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Old 04-05-2010, 10:01 AM   #1
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Problem with my Aussie Locker

Well my Aussie locker has been acting up lately and making a awful sound while I'm driving. It's less then a year old and me being the dummy that I am I don't know where my receipt is.

It almost sounds like grinding but my guess is the teeth aren't catching or something. I'm not in 4wd just normal driving on the road. I'm wondering if i can just take the internals of the front differential out and take the shaft from the transfer case off and it be safe to drive. No offroading until I can get another locker.

Also I'm thinking about switching to manual locking hubs. I don't mind the fact that I'd have to get out to put it in 4wd. I feel like if I get another Aussie I might have same problem. Also about how much will it cost to switch over to manual hubs. I have a dana35

Thanks

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Old 04-05-2010, 10:28 AM   #2
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open it up and see what it looks like. do you still have the stock spider gears? if so, put them back in for the meantime. aussie will sell you specific parts separately so you can repair it. the only manual hub conversions i've seen are $$$. if you find a cheap way, let me know, cause id be interested.

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Old 04-05-2010, 11:12 AM   #3
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Does the noise happen when you are driving strait or turning?
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Old 04-06-2010, 03:43 PM   #4
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The noise happens when I'm driving straight and also while I'm turning. I've taken it apart and everything looks normal. When i spin the tire you can see the teeth skipping over one another. Don't know what that means, but that's when it makes the noise.

It's not drivable at the moment because of the noise and don't want to cause any more damage. I'm looking for a temporary fix until I can get another locker in there. That's what I'm trying to figure out. Is there any way to drive the Jeep with no internals in the front differential and taking the driveshaft for the transfer case to the front diff off.
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Old 01-08-2011, 04:38 PM   #5
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Bump

Would like to fix the locker it worked great just can't think of what's wrong with it
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Old 01-08-2011, 04:42 PM   #6
Knows a couple things...

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Remove the front cover and see if you can see any visible damage. Look at the ring & pinion gear to make sure their teeth are all ok. If they are, odds are the teeth inside the Aussie are damaged. You can remove the Aussie but the spider and side gears that the Aussie replaced will have to be reinstalled to keep the axle working properly.

Manual hubs are expensive to install, well over $1000 for a conversion kit. And if you decide to go with them, your front axle is a Dana 30. A Dana 35 is only used in the rear. I'd only install manual hubs if you wheel hard enough to expect front axle breakage and want to be able to disengage the axle from the wheel so you can drive home with the damaged axle.
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Old 01-08-2011, 05:00 PM   #7
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I took the Carrier out and was hoping to take it to my local shop to see if they can look at it, but they closed down. I tried getting in touch with Aussie but I don't have the measurements from the install.

The teeth are a little rough on the pinion but the ring looks fine.

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