I installed an Aussie locker in the 8.25 of my 98XJ. It was possibly the most important mod I made to the Jeep -besides a winch. I was very surprised at how little I needed to us 4WD. In fact, I was able to do several difficult trails in Moab in 2WD! Installation was very easy. There is no need to remove the rear wheels, in fact, having them in place is advantageous when it comes time to remove the C -clips. There is no need to disassemble your brake components either -leave everything back there intact.
Here is a short list of how I installed mine:
- Chock the front wheels and jack up the rear end just enough for the rear tires to clear the ground.
- Remove the diff cover and let the gear oil drain.
- Put the t-case in neutral so that you can spin the axle to remove the retaining bolt that holds the spider gear shaft in place.
- Remove the inner C- clips -it helps to have a friend push/pull the rear tire in and out while removing the clip.
- Slide the axle assembly out of the axle tube just enough for the axle to clear the spider gears -let it rest there.
- Remove the spider gear assembly in its entirety.
- Assemble the locker per the instructions that came with it and install it.
- Very gently slide the axle shafts back into place.
- Reinstall the C -clips -there's less space to snake them into place, but it's not awful.
- Clean, RTV, and install the diff cover.
- Place the vehicle back on level ground and add the correct amount and weight of diff fluid.
- Go for a drive and be surprised by how rarely you need to use 4wd.
This isn't a comprehensive list at all, be sure to clean and inspect everything before removing the spider gears. Also, have some axle grease close by to help hold things together when you are going back together with everything -a small dab will do the trick. It seems that installation of the small springs that come with the kit can be either a bear or no problem at all. I've read the experiences of others, I had no trouble with them at all.
I could ramble on and on, but the "Vermont Jeep Girl" does a great job demonstrating the install in a D35, which is virtually the same. She does it on the bench to make it easier to film, you don't need to do this.
Some things to consider:
With both wheels attempting to push the vehicle forwards, you will observe an increase in understeer on the trail. This understeer can become oversteer on we or icy pavement, especially when turning, adjust your driving habits and be aware of road conditions. Others will tell you that if you "know how to drive" it's not a problem. This simply isn't true, the Laws of Physics do not care if you know how to drive or not (of course, being a poor driver can amplify these issues). Contrary to popular belief, having both wheels spin at the same rate can reduce traction at the locked axle. For example, if you are on a slick, off camber road, expect the locked axle to favor sliding down the hill. I only mean to make you aware of some of the things you can expect from a lunchbox locker. I was very happy with mine and I'm sure you will be happy with yours. Just be aware that the driving dynamics of your Jeep will change.