So, everything goes smoothly until now. I wish I wouldn't have bought a locker...now I probably won't have a truck for weeks.

Here is the problem...




The pin won't fit between the spacers. I talked to a guy at Aussie and he told me that they have several of these out on the street and with no problems...then why am I having this problem???

I used the stock thrust washers (one on each side) and cleaned the surfaces really good.

So why is this happening????????

 

I've had the pin go in close to snug....perhaps only .001 or .002 air gap.
Your thrust washers are just a tad too thick....the dealer can get thinner ones in 2 days time but you have to know what thickness you have there and guesstimate what thickness to order. Measure the washers and get back to this thread....I bet they're .067" both.

....edit...if it's really close then some people might try taking a sheet of 100 or 200 sandpaper on a flat surface and swirling the coupler spacer evenly on the paper and remove 001 or 002 at most. Done to both sides it could allow the pin to pass thru.

I believe Jim is the main tech there and I would recommend asking him if there is an issue with a cross-pin that slips thru with little to no gap at all. They recommend a measured gap of .006~.020" for some unspecified reason.

 

Thanks Zuk.

I spent 30 minutes on the phone with a nice gentleman from lock-right who also helps with aussie too.

Anyway, they are 0.048 thick. Both exactly the same. Well actually 0.001 off...but still pretty dang close.

So, what do you recommend?

 

i did mine with sandpaper when it didnt fit. But i used pretty fine stuff...

 

I would have to take quite a bit off though. And then it would be uneven and ugly.

 

then measure the diameter of the pin and the gap between both sides and determine how much you need to take out of the sims. Go to toyota and buy new ones...

 

.048" = 1.22mm

.040 = 1mm (very close)
so that means every .004" equals .1mm


you have a 1.22mm right now.....seems like .004" thinner should suffice so subtract .1mm from 1.22mm and you get 1.12mm as the target value.
just a good guess though at this point.

To be safe, it would seem like you could take the dial calipers and measure the gap that the pin has to slide thru....and also what is the diameter of the pin itself?

 

I went to the dealer and they had 1.22mm and 110mm thickness thrust washers. I ordered the 110 thickness...dead on!

They will be here tomorrow!

Anyway, i think i'm going to take it into a shop and make sure everything is fine and in good condition.

 

dont take it to a shop now.. your almost done! plus how could you have messed it up? were you trying to beat that pin in with a hammer?

 

you're going to love having a locker.

 

Yes you are going to love having a locker. Matt16 it seems like your write up has inspired many, myself included
I love my Aussie

 

Thanks matt! I can't wait till I break it in...2 wheel burnouts!!! yay!


Here are some pics....









Goes past on 1 side but not two???


This is where my problem is!

 

Careful doing locker donuts. I flopped my truck when I was doing locker donuts. Back tire sunk into a pothole that I didn't see, my donut was stopped dead and I went arse over tea kettle. Even the cops laughed at me. I don't know what they were laughing at thought because I didn't think it was so funny.

[/sounding like old fart]

Did you get your thinner shims yet? I'd want the clearance between the cross pin and the locker bits to be the same on each side or else you may find turning one way is more troublesome than the other.

 

you get those new washers ordered yet?

 

sandpaper is looking better and better...