Hi-

Some feedback on the installation...

The supplied instructions (labeled for a Dodge) say that a replacement cross pin was included with the locker and must be installed with the 98+ Ranger D35 front locker kit (XD-13535). Since my kit did not include a replacement cross pin, I called and was told that this is incorrect and the original pin should be reused.

The tolerances called out in the instructions could not be met in my diff. Side gear to cross pin tolerance is listed as 0.006~0.020" but mine was 0.024". Center distance was 0.180" which was also out of tolerance (0.145~0.170"). I was told over the phone that these clearances would be OK.

The 2nd locker drive gear physically would not slide in between the assembled side gear and the 1st drive gear. I had been warned that the opening in the Ranger D35 carrier might need to be enlarged but this was NOT the issue on mine. After several calls to Bill and Tim (in Colorado), I was authorized to turn 0.006" off the nose of one side gears to allow the installation of the drive gears.

Spin test: I carefully tried the method in the instructions several times on both sides and in both rotations but the locker absolutely refused to disengage with light-to-moderate torque applied. The advertising and instructions seem to imply that the locker will easily disengage. It finally did after a LOT of effort. I am convinced that the grease (called for in the instructions) between the side gears and drive gears was the culprit. As soon as axle lube got in there, the unlock was very easy.

I have since talked to a couple of other owners whose new Aussie Lockers also "failed" the spin test. In both cases, they dutifully disassembled the diff, rechecked the installation and found nothing wrong. This is no small task on a 98+ Ranger because the front axle must be removed from the truck to open the diff cover. In the end, it turned out that they had the same problem with the grease and the locker worked fine once gear lube got between the teeth.

In my opinion, the crosspin and spin test information needs to be improved. Also, the Ranger installation is different enough that it deserves its own set of instructions.

Thanks, Bob

Thank you for the feedback. We will review your observations and suggestions with our technical service and Australia engineering and come up with a new approach to the XD13535 installation procedure. In the interim we have indicated an "out of stock" condition on that model so we can supply customers with a manual that makes the installation as easy as other models.

We apologize for the inconvenience you had.