Aussie Locker Install writeup

[Wanderer]

AUSSIELOCKER for FORD Twin Traction Beam Dana 35

Model # 13527
1988-97 Ford Ranger/ 1991-95 Explorer 88-91 broncoII
1988-97 Mazda B3/4000/ 1988-95 Navaho
Application 4.0L/2.9L (most 2.3L have a TTB D28 hybrid)
Link to axle identification AND TTB D28 Hybrid info
http://www.therangerstation.com/tech...ont_Axles.html


Upon receiving the AussieLocker #13527 I was surprised by the overall size and weight of the unit. It appeared to be very well designed and thought out, it was heavier than I had anticipated, a very good sign it would withstand the punishment I wanted to subject it to.


I had 2 spare carriers and housings for the ttb35 and decided to discover once and for all if there was a difference in the carriers from the 3.27 and the 3.73 (some said there was a difference). I am here to confirm that there is no difference in the carriers when it comes to installing the AussieLocker from www.offroadlockers.com

The install was pretty straightforward. Follow manufactures instructions for removing your carrier/housing and set it on your workbench. Remove the carrier from the housing (remember to mark the bearing caps and shims for orientation and left or right side),Remove the spider and side gears,saving the shims from under the side gears.


Install the shims from the side gears under the axle gears. Install one set of the axle gears, spacers and cam gears onto the side of the case with the ring gear. Next install the axle gear on the open side of the carrier, then the spacer and cam gear (mine fit without any grinding on the carrier at all but some may require a little clearancing of the window.


DIFFRENCE FROM MANUFACTURER INSTRUCTIONS!!!

DO NOT INSTALL FACTORY ‘C’ CLIP!!-see Below

At this stage of the install I discovered that its best to go ahead and align the cam gears with the crosspin and install the crosspin into the carrier (you will have to take a screwdriver and slide the upper spacer out of the way). This makes it easier than to try to install the pins and get the cam gears to spin in the carrier. It takes a bit of fiddling but should be possible for you to do without having to grind on the sides of the carrier. I then installed the pins with the recess oriented towards the open side of the spring groove slid the pins into place and installed the springs.
Then I flipped the carrier over and did the same for the other side.

I checked my clearances and everything fell within the .145-.170.
Mine was .150

I then reinstalled the carrier into the housing and torque to manufactures specs.



C-CLIP ELIMINATOR.

The factory C-CLIP in this axle does not fit within the spacer cup. I tested this and had to disassemble the locker with it installed and it was VERY difficult. Instead I used a spring that we (www.rrorc.com) discovered works perfectly for removing the c-clip yet making sure your axle stays well seated in the carrier. We did this for 2 reasons.
1. The locker will not work without it.
2. Its easier to change the middle shaft if you have a breakage (don’t have to take the carrier apart on the trails.)

With some reference and several other friends we discovered the proper spring in length and dimentions is available at Tractor Supply Company and its spring # 3534278 and it works perfectly.

After I got it reinstalled, fluid filled (80W90) and back on the tires I followed the manufactures instructions for the “spin” test and confirmed that it unlocks as it should.

Then I got it out of the garage and took it for a test drive, no sudden engagements/lurches/jerks from the front end. It was totally seamless when it locked or unlocked And MAN this thing is QUIET!!


I highly recommend doing this upgrade to your ranger/explorer. It was the best money spent for the highest quality available, and CHEAPER than anyone else on the market!!

I would like to also thank Bill Cole President of TorqMasters.com for his assistance in discovering the correct application for this vehicle. As of the date I did the install they did not have a product that had been a proven application for the years/models and this was a prototype install that went PERFECTLY. Everybody with a ranger/explorer that’s looking for a quality locker for a reasonable price needs to call Torquemasters at 585-723-1489 or visit them a their online store www.aussielocker.com

I would also like to thank Torq-Masters for their unpresidented level of customer service and a mentality to make any customer they have absolutely happy with their purchases!

[Les M]

3.27 -3.73 carrier difference is in the machined surface for the ring gear only.