I got to thank you Zuk for your instructions, they were invaluable in figuring out how diffs are put together.

I should clarify that the locker makes noise when it coasts with the clutch in around a tight corner. Same noise as when you do the locker test to see if it is working. I'm sure its a normal noise, at least for those of us with 5 spds.

I think this is because of the inherent play in between inside couplers in the locker itself and the crosspin when there is no torque being transmitted from the driveshaft. In the absence of torque, the inside couples can move back and forth a bit and the ouside couplers can engage the inside coupler quick enough to make a click sound. When under power, the speed at which the teeth engage is dependent on wheel speed instead of the the force applied by the springs between the inside couplers. If you are lost, worry not, I would be amazed if anyone understood what I was thinking here.

Maybe this will help, should anyone wonder what I'm talking about:

 

Ohhh....clicking around a corner is normal for both a 5 speed and auto. Get some of the synthetic 75W-140 and I bet it gets a little quieter.
The link has been updated.
ZUK

 

I've got some 80W140 in there, the noise is so quiet that no one but me has ever noticed, except in a echo-y parking garage.

 

Done!

 

bahh, finally...
Getting my aussie soon, this will help.
Thanks matt !!

 

what about the front is it the same design on an ifs truck? can you remove the 3rd the same way and use these instructions?

thanks

 

the ol "same thread bolt drum undoer thingy" that didn't work no more than fly to the moon! ahhahah I torqued on it a few turns and the metal tore away.
Got the third out anyway. Now I have to find a new drum

 

Afraid not. The front diff is quite different. You first have to remove the IFS assembly from the frame.

 

I've been wanting to put the aussie in my 94' pickup for a while but ive never once worked on a diff and really dont know all too much about basic mechanics quite yet. would it be recomended that i pay someone to install it or is it easy enough to figure out in a weekend for an ignorant newbie? any words of advice would be completely appriciated.

 

You should be able to get thru it in a weekend....just reference those links I posted farther up this thread. ZUK Let us know how it went.

 

Thanks to the authors and contributors of this thread. My Aussie came in yesterday and I'm looking to install at the earliest opportunity, perhaps this weekend.

I've read through the documentation here and for the most part it makes good sense. I have a couple of questions.

1) How can one determine if the thrust shims which are to be reused with this install are suitable or if new ones are required?

2) I see in Zuks nice write up that he "snugs" up the adjusters on a higher mileage rear end. http://www.gearinstalls.com/aussielocker.htm If anyone has some guidance as to how to do this without Zuk experience, I'd like to hear how I could safely accomplish the same thing, as I suspect my rear end had seen well over 130k miles.