Step #3 - Remove lockout hubs. You will have to use a closed end wrench unless you want to removed the end and guts of the hub. We tried it both ways. I would say the extra 5 minuts of using a open end wrench is worth saving the pain of putting the hub back together.

Step #4 - Remove 2 lock nuts and washer that are behind lock out hub. They are very good size and we could not get any tools back there. So I followed suit with past owners and tapped the with a flat chisel. They should not be too tight.

Step #5 - Rotor should slide right off now. Remove dust cover and loosen the nuts holding everything together.

 

Step #6 - Once this is done and you have everything off on both sides the axles should slide right out. You really only need to put about 6" out but we removed because I am replacing the u-joints while I have it tore down.

Step #7 - Remove carrier and sit on bench/table. There are 4 bolts hold her in. Be careful not to let the races fall off when you lift it out. Also mark everything on how it came out. Stuff starts to get important here.

 

Step #8 - Now that the carrier/chunk is on the bench the fun can begin. You will need to vise up the carrier. Be careful not to hurt the gears. Unbolten the ring gear. Don't worry it will not fall off. Once bolts are out set back on table and use a rubber mallet to knock the gear off the carrier.

Step #9 - Using a 3/16" punch knock the roll pin out that is in the little hole on the larger end of the carrier. This knocks the pinion shaft loosing.

Step #10 - Remove the spider gears, etc. from the carrier. It is really an open carrier now.

 

Step #11.1 - Install AUSSIE!! You will need to get some axle grease to help hold stuff together. You will reuse the thrust washers. Install the splined parts of the aussie unit on each of the carrier with the thrust washers against the carrier.

Step #11.2 - Install the "middle" sections. They will only go 1 way due to the clearance of the carrier.

Step #11.3 - Install pins into locker. Install springs. Done!

 

Step # DO NOT DO - Just like anything stuff goes wrong. In our case my torque wrench things 80 lbs is 800 lbs. As a result we broke a bolt.
:dance::rofl::thumb::banghead:unk: Luckily we had a "spare" dana 30 under the cj.

 

Step #12 - Reinstall ring gear.

Step #13 - Reinstall Carrier. Good idea to clean gasket surface before installing carrier. Also check the carrier and everywhere to make sure no trash made its way into something.

Don't she look pretty!! unk::thumb:

Step #14 - ? - Do everything you did before now backwards.

 

unk:

 

Nice work Nick.

 

Still need to press the old u-joints off and put in the new ones. We broke a hammer trying to get them off but that is what happens over 30+ years or mud and water.

After that I can put back together and hopefully install in the cj with the new lift.

 

I should have been a hand model...

 

Cool write up. Thanks for posting. You will love the Aussie, I have had mine over a year and the difference is night and day on the trail. You can now walk up stuff you needed momentum for prior.

Jeff