Installed a Lock Right locker tonight in my front Dana 30 diffy. All went well except that the locker won't turn within the carrier.
The piece called the "driver" has flat sides (on top and on bottom in the picture below), and hits the carrier as the flat section becomes round and too large to rotate within the carrier.
Pic and video below.
* 99 TJ Sport, 4.0L
* My thrust washers are installed, the same ones that were originally in there.
* Dana 30 front axle
* Lock Right locker model # 2210
So, possible solutions are...?
. Cut the locker down -- doesn't seem like this should happen as I'm compromising a critical part. Don't want to do this.
. Remove everything and cut the carrier at the points where it rubs -- how would one do that? I'm assuming the carrier is hardened steel.
. Thicker thrust washer -- don't know if this is wise as I'm supposed to keep the same thickness as original.
Here's a picture of where the locker (the driver piece) is hitting the carrier.
Here's a video of me turning the locker. The pinion isn't installed yet, as I'm using it to turn the locker. It stops in both directions because the locker (driver) is hitting the carrier. This shows it hitting at the top of the carrier, but the same is happening on the other side too.