Death of a lunchbox locker - Off-Road Forums & Discussion Groups
Jeep-Short Wheelbase All discussion of short wheelbase Jeeps: CJ, TJ, YJ and JK

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post #1 of (permalink) Old 06-26-2009, 03:56 PM Thread Starter
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Death of a lunchbox locker

When I bought the D44 rear it had a Detroit E-Z Locker in it. It worked for about six months, but I was never entirely satisfied with it. The clanging and banging on the street were terribly annoying, and I couldn't help thinking about how it was wearing my tires. Even with the tire pressures equalized to the best of my ability, it would always pull lightly one way or the other when driving in a straight line.

Lately it took to jumping two or three teeth at a time, and one cold morning didn't hook up at all until I very gently eased the clutch out. Then, at The Bash, it just spun with a nasty ratcheting sound when I tried to climb a sand hill.

Just in the last week I got time to take it apart and here's what was wrong:

DSCN3546a.JPG

One side thrust washer was worn so thin that it was disintegrating. The play put the dog clutch a little too far away to engage fully. Also, the cross shaft was so worn that it was probably letting the clutches out of alignment.

And this is why it's headed form the scrap bin:

DSCN3550a.JPG

DSCN3550b.JPG

All four of the alignment pin holes were cracked through on the spring side of the clutch, and three of the receiver holes were also cracked. I don't know what caused the cracking, but my guess is that the worn cross shaft let the clutches flop around which put too much strain on the pins. Anyway, Will sent a set of spider gears, so now it's an open differential again.

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Last edited by Jim_Lou; 06-26-2009 at 04:08 PM.
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post #2 of (permalink) Old 06-26-2009, 04:54 PM
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Jim, it looks like someone had too much side shims in the thing.

We used to do that drag racing to keep both rear wheels locked longer so if you got a little sideways (Fishtail) the locker wouldn't lock and unlock rapidly and you could stay in the power.

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post #3 of (permalink) Old 06-26-2009, 05:37 PM Thread Starter
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There was only one shim in each side. The one in the picture wore so thin that it broke into three concentric pieces.

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post #4 of (permalink) Old 06-26-2009, 07:06 PM
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ive never seen a side shim do that. If had to guess that rear ran very low on oil for a long time. I would be looking at my pinion bearings.

Unless that side shim looked something like that when the locker was installed, it shouldnt have gotten that bad.

The side gears shouldnt have been turning around that shim all the much with the locker.

But at least you found it before it found you.

My thoughts on lunch box lockers. They belong in a box. Right on the shelf.

What????
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post #5 of (permalink) Old 06-27-2009, 05:34 AM Thread Starter
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I put new bearings in when when I re-geared it. The old ones werennt burned, but were slightly pitted. The big mystery to me is that the cross shaft was loose in the carrier. The holes in the carrier were oval by .007". I put it back together with Loctite 660 fiiller to make up the difference. Hope it holds.

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post #6 of (permalink) Old 06-28-2009, 09:56 PM
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Quote:
Originally Posted by Jim_Lou View Post
There was only one shim in each side. The one in the picture wore so thin that it broke into three concentric pieces.
Kerry and I saw that picture and were AMAZED!

Just one of those things I can't explain!

The only time I've seen cracks from the connecting bolt holes like that was when extra shim pressure was used,
So you have a REAL oddity there!

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post #7 of (permalink) Old 06-29-2009, 09:44 AM Thread Starter
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It's in the scrap bin now. Think I should have it bronzed?

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post #8 of (permalink) Old 06-29-2009, 01:58 PM
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I tried to tell you that no Jeep will take the abuse you put yours through!
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post #9 of (permalink) Old 06-29-2009, 05:46 PM Thread Starter
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Why, I baby that thing as if it were made of gold!

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post #10 of (permalink) Old 06-29-2009, 06:31 PM
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I know of one case where PowerTrax warrantied an out of warranty LockRight. A friend of mine broke his and called them (just for giggles and grins) and described what happened and they were interested in inspecting the locker. He sent it to them and they sent him a new one. I don't know exactly what was said and I think it was out of warranty by 6 month or so. Might be worth a phone call!

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