i figured out how to automatically cut the circuit for daily driving: tie it into the 4wd indicator. that way, i can't accidentally bump it, but if i need it on, no replacing a fuse

half-way there.

marlin crawler sent me the wrong wiring harness. i ordered "rear" and "rear" showed up on my shopping cart, invoice, and packing slip. i got the front, high-pinion plug. the big issue is that the connectors look almost identical until you try to plug them in. on top of that, i already molested the harness, tying it into my circuit. and this is after they shipped my package via fedex, when i specified usps.

and if that wasn't enough, i can't unlock my locker. i needed to take an extra 2-3mm off the side notch. part of that was not having the gasket to measure from. the arm hits the side of the axle housing. so now i'll have to do everything again, including pulling the axles, pulling the axle housing out, etc. the only thing i won't have to do is stud placement.

oh, and if that weren't enough, the locker motor is acting up. it gets stuck when switched to lock. and with the rain this week, i can't work on it until next weekend

That sucks. I know there is a company making a manual control for the locker cable actuated if that would help. I can recall the company at the moment.

Wow, Ian,.... that bites, for sure! I'm sorry man. You'll get it figured out, hopefully without finding any 'serious problems' therein. Dang, ..when it rains it pours then, eh?

The added distance of the sealer caused some 'biting' issues?

Never mind, it's made by chilkat and is $579!!! Its got nice machined parts

very nice truck! i need some advice from someone though. i have a 92 sr5 with 5.29s and runnin 35x1250s what is the lowest gear i can change it to in order to get better fuel economy. i love the 5.29s but they arent really the gears i need. i drive on the highway alot to and from work and also when i drive home to see my family occasionally. i was told 4.88s would be good. its automatic but when im driving. i have to go 80 mph just to get in the last gear. so i def need to change

don't worry, jimmy; all our work was not for nothing. i learned so much that i was able to do 2 days of work in one evening (tonight). the axle housing is bare, the gasket surfaces are smooth, and i'm ready to grind the last little bit. dammit.

anyway... i think i'll be able to get this all wrapped up before tomorrow night. that'll be nice

Wow, that sucks having to tear it down again, man! But WOW, so sweet to know how to fix it! lol. Glad you've got a solid line on what happened, etc.... Can you share in great detail with us as to the specs, etc., that got in the way/were involved during fix?

Best wishes, Ian.... was wondering where ya went... then thought, "OHHHHHH yeahhhhhh!" lol. KILL IT, SIR!

yeah, i just needed to grind out more of the axle housing to clear the actuator arm. if you look through the e-locker conversion instructions, you'll see where it says to place the gasket and grind away where the gasket doesn't cover the surface. well, i didn't have the gasket, so i estimated. problem was i didn't grind enough away. so hopefully by this evening i'll have everything back together and working correctly.

Three times the charm.
Hope this is your last time.

three times?!? i hope this time (2nd time) is the last.
anyway, later today i'm gonna order the correct wire harness from someone else. and possibly a few low-profile drain plugs

Wow, that bites! But, you're getting it and hopefully nothing was damaged, etc., etc. .... Should be good to go(Minus a lil knuckle flesh gone maybe? lol). Best wishes, Ian, I hope this 3rd time's the charmer, as mentioned

I thought you said you tore it down twice. My bad, hope you get it ironed out.

Damn dude I guess it fitting so nicely without grinding very much was just a little too good to be true...I would assume that's why most guys used the gasket as a guide and ground out so much...

Sorry that you have to tear back into it and grind off some more but I'm glad that you learned enough to do it much more quickly.

Also, bummer about the Marlin wiring harness I can only hope that they make it right and send you the correct one without any issues. Keep us updated because if they don't make it right, I would definitely think twice about ordering from them again. Good luck man!

I got a feeling he's out there, right now, checking, checking and rechecking before he slaps it back in, without any breaks, refusing even a sandwich or cold beverage in a type of "I'll beat you" hunger/thirst strike! NO? hehehehe.

Anxious to hear how everything is going, that's all

you guys are awesome. i'm done with everything except bleeding the brakes and filling with oil. i'll get to that tomorrow. it'll be streetable this week so i'm looking forward to driving it for the first time in two weeks

Pssssst.


Get the e-locker skid plate, i just did.

i'll just borrow yours

nah, it's another thing to get before the 22nd.

Yeah I hear ya.