Aussie Locker ...puked

[xjintx]

Sorry for big images but wanted detail for you.
I posted and asked about initial problem before heading out.

OK, my rear end took a “PUKE” at Moab this past week.
I must note there was a popping / release noise since I first drove this D44 with the Aussie installed. Not just off road but driving at any speed over 30mph.

Worked OK locked front and rear (Aussie in front too) did some OK obstacles. Then at one obstacle it just popped kept popping and did not move. After winching and proceeding on trail I could not give it any power… just popped. I assume it was defective??? Possible bad install? Limped to camp with front drive.

Any help appreciated

GEARS

Aussie possible break 1

Aussie 2

 

[Mark817XJ]

Hey Rodger, glad to see the pics finally. You can still see gear marking compound on the gears..

I'd like to measure backlash and run a pattern on the gears before we take it apart any further.

I would love for someone to chime in, I installed the gears and locker for Roger; everything went together fine. Gears are all within tolerance, all new parts used etc.

After the install with minimal miles on it, enough to not even wear all the marking compound away, the aussie takes a dump.

I will verify the integrity of the gear setup and the torque on all of the bolts but assuming they are all fine what could cause the aussie to do this?

I'm going out on a limp here but even if the gears were way out of wack how could that damage the aussie?

 

[Mark817XJ]

I will measure and picture axial run out, back lash, gear pattern and verify torque on everything, assuming all are fine what do yall think?

 

[wheelinscott]

it looks to me that the clearence between the drive gears is too much. when you installed the locker did you measure the gap between the two drive gears? that has to be within spec. went though this with a rear lockright in my 8.25

 

[Beezle]

Huh, pretty close to the same story I have. I was in Moab with the colorado chapter about a week ago and my aussie did the same thing. Started up a steep hill and heard a loud bang like it was unloading then after that it was making all kinds of ruckus and would not lock up. Luckily I had my old spider gears with me and replaced the locker with those on the trail.

My locker was all in spec according to the measurements I took with the feeler gauge.
I don't have any pics but there are 3-4 teeth that are rounded off not allowing it to fully lock up.

Got in contact with aussie and come tuesday I'll be mailing it to them so that they can inspect it for a warranty claim.

 

[xjintx]

Beezle... what rear end do you have D44?

My Aussie in the D30 front worked fine.

Did you just call Aussie? From now on... if I keep Aussie I will carry spare spiders

I had to ride shotgun the rest of the week... could not see buying new spider gears in Moab... they wanted to much and I was not even sure what was really wrong until we got it open... later.

 

[Beezle]

I have an 8.25 with 4.56 gears. I called them and they left a message for the warranty guy. It seems like they like to communicate through e-mails better as thats how I got my "RMS" number to send it back to them.

According to everything I've read about Aussie they have a really good reputation so hopefully they will replace it.

Yea, I figure with any lunchbox type locker carrying spare spider gears and cross shaft is a good idea.

I'll keep ya updated once I send it back and hear the verdict.

 

[Mark817XJ]

I just got back from Rogers and the pictures actually make it look worse than it was. We pulled it all apart but measured it first.

Gear backlash was at .018" and pinion bearing pre-load was at 2in-lbs. The gear pattern shows the pinion being to shallow. When I originally setup the gears I had .008" of backlash and 15in-lbs of pinion preload but thats going from memory, I'd have to find my notes.

The original pattern looked really good so I'm curious as to what went wrong.

All that aside it should not have affected the aussie; we measured it according to the directions and numbers were all in spec, but I suspected that because it was a new carrier and new thrust washers.

I think the aussie just broke. I don't understand why but I cant find anything that would have done the damage. The gears were out of spec but again, how would that affect the locker?

Our plan is to warranty the locker and then set the gears back up and reinstall the locker.

Axel shafts and the splines looked great, everything looked fine other than the locker. I'm pretty well baffled at this point.

 

[Mark817XJ]

Actual I just found the problem. I would have argued that we could not have installed the wrong model number locker but it appear we have. I compared a brand new XJ Dana 44 Aussie with what we just took out of Rogers and the side gears are identical in every way but the center gears are different. Not by much but they vary in thickness by about .200".

Maybe there are different lockers for the full width Dana 44's and the XJ Dana 44?? The spline count would prohibit us from putting in any other locker, on these two they are the same.

 

[WaXJ_Skier]

Maybe there are different lockers for the full width Dana 44's and the XJ Dana 44?? The spline count would prohibit us from putting in any other locker, on these two they are the same.

Nope they are the same part, you probably ended up with a poorly machined center or got a "mixed" locker.

 

[Mark817XJ]

Nope they are the same part, you probably ended up with a poorly machined center or got a "mixed" locker.

That's good, maybe we can still use the warranty then..