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LOCK-RIGHT™ Performance Locker Installaon Manual

Four-pinion dierenal; two-piece capped case

Typical of Suzuki Samurai (SJ-413), SJ-410, LJ-80, Sidekick, etc.

Introducon.................................................................................2

Background Informaon..............................................................3

Installaons Covered in Manual...................................................5

Preliminary Steps...........................................................5

Removal and Disassembly..............................................5

Removal of Dierenal Case.........................................6

Disassembly of Dierenal Case...................................8

Inspecon of the Parts...................................................8

Preparing the Parts for Assembly.................................11

Assembly of the Parts into Case..................................11

Third Member Final Assembly.....................................16

Assembly Inspecon....................................................17

Third Member Installaon...........................................18

Vehicle Final Assembly.................................................18

Tire Diameters............................................................................18

Tesng the Complete Installaon...............................................19

Driving Your Vehicle....................................................................19

Warranty Informaon................................................................20

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Summary of content (20 pages)

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LOCK-RIGHT™ Performance Locker Installation Manual Four-pinion differential; two-piece capped case Typical of Suzuki Samurai (SJ-413), SJ-410, LJ-80, Sidekick, etc. Introduction.................................................................................2 Background Information..............................................................3 Installations Covered in Manual...................................................5 Preliminary Steps...........................................................
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Introduction Welcome to the growing family of LOCK-RIGHT owners! This manual will help you install your new LOCK-RIGHT automatic 100% full-locking differential. When the installation is complete, your vehicle will have extreme traction! We trust that you will be pleased with its performance and thank you for your confidence in our products. LOCK-RIGHT installation simply involves disassembling and re-assembling the differential case, replacing a few parts in the process.
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responsible manner. Be sure to read and understand the driving information in the LOCK-RIGHT Vehicle Owner’s Manual! pinion shaft before proceeding. A word about pinion shafts: Some models of differentials use shafts with circumferential oil grooves for oil distribution, while others use shafts with flats. The shafts with flats are re-used, while those with grooves are not. If new shafts are provided in your kit, use them. If no shafts are provided, use the existing shafts.
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( ) = PARTS IN SOME MODELS THRUST WASHER COUPLER (SIDE GEAR) DRIVER STOP PIN; SPACER PINION SHAFT(S) (BLOCK) BIAS SRPINGS Figure 1 LOCK-RIGHT Exploded View 4 DRIVER COUPLER (SIDE GEAR) THRUST WASHER
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c) Jacking up the axle; securely resting it on jack stands; d) Removing the tires (some axles) e) Disconnecting the brake lines and emergency brake cables (some axles) f) Pulling out one or both axles a few inches. LOCK-RIGHT Installations Covered in This Manual Removable third member axles. Typical of these are all rear and some front axles in various models of Suzuki 4x4 vehicles.
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Removal of the Differential Case from the Carrier 1. Remove the third member from the vehicle as described in the shop manual. Follow all safety precautions. 2. Check to be sure that the third member is in good condition and that nothing is loose, worn or scored. Rock the ring gear back and forth to get a “feel” for the backlash and check to see that it appears to be set up properly. If any out-of-spec conditions exist, be sure to correct them before subsequent re-assembly.
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Mark the carrier and bearing cap on the ring gear side with one punch mark and on the other side with two marks (Figure 2). The caps are not interchangeable! Also mark each bearing adjuster directly under the lock with this same mark to note its side and rotational position. This mark is very important to correct re-assembly! 4. Remove the adjuster locks. (See Figure 3). Be sure that each adjuster is marked at the lock with the correct number of punch marks for each side.
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7. Remove the differential case and ring gear assembly from the carrier along with the other adjuster and bearing race. Inspection of the Parts NOTE: These steps are important. The LOCK-RIGHT utilizes your case, side gear thrust washers, pinion shaft and axle shaft thrust block, (if used), and they must be in excellent condition. The spider gears and washers are not used. If the following inspection shows that anything is bad, buy new parts from your dealer! 1.
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Figure 4 New side gear Figure 5 Moderately used side gear 9
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b) Moderately used side gear (Figure 5). Note that some polishing is evident near the top but that the sides of the tooth remain slightly rough. c) Heavily used side gear (Figure 6). Note the depression worn in the sides of the teeth, tops “rolled” smooth, and highly polished surfaces. Will not function—should be replaced. 3. Inspect the side gear thrust washers. They are important to the correct positioning of the LOCK-RIGHT parts. If they are excessively worn or are cracked, obtain new ones. 4.
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5. Inspect the case for any chips, cracks or similar damage. Also inspect the bearings. If the case or bearings look bad, replace them. However, if you do, remember that the marked bearing adjuster positions no longer will be correct; the ring and pinion backlash and bearings pre-load will need to be reset with a dial indicator as described in the shop manual. LOCK-RIGHT Installation Preparing the Parts for Assembly Coat the teeth of the drivers and both sides of the thrust washers with medium grease.
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Figure 8 Place washer and former top gear into case Figure 9 Place drive on gear with spacer in center 12
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Assembly of the LOCK-RIGHT Parts into the Differential Case Summary of steps in this section: a) Install ring gear side coupler and washer b) Install ring gear side driver and spacer c) Install pinion shaft block and shafts d) Install springs and pins e) Install pins and springs another driver f) Install other driver and spacer g) Install other side gear and thrust washer h) Install case cap 1.
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3. Install the pinion shaft block and pinion shafts (see Figure 10). Note that the pinion shaft block is not a precision part and that the holes may be drilled off-center such that the block is thicker on one side than on the other. The spacer may tend to bind between that side of the block and its corresponding side gear. To check for this condition, place a spacer in the center of the driver and install the pinion shaft block using the long shaft.
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present one. Re-install the block with the ground side down and continue with your installation. 4. Insert a small spring into a large spring and place the assembly into one of the large holes in the bottom driver (Figure 10). Repeat for the other hole. The grease placed in the holes earlier will help hold things in place. 5. Place a spring assembly into each hole in the other driver. Place a little more grease on top of the springs to help hold them in place (see Figure 7). 6.
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8. Place the other side gear (the one that formerly was in the bottom of the case) onto the top driver with the teeth meshed and then place the second thrust washer on it (Figure 12). The smoothest side of the washer is placed next to the gear. 9. Place the case cap onto the case in its marked rotational position. Line up the holes and install the bolts. Torque them to their proper value. 10. Install the ring gear in its proper marked rotational position and then tighten the bolts. 11. Inspect your work.
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5. Install the correctly-marked cap. Use the bolts as guides by turning them in two threads or so and then sliding the cap down to meet the case. Be sure that the cap threads fit into those in the adjuster. Do not force anything. the cap should slide down very close to the carrier surface. Tighten the bolts until they are snug (see Figure 2). 6.
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chips can interfere with the operation of your new LOCK-RIGHT. 3. Remove metal chips from the drain plug if it is magnetic. 4. Install a gasket and/or sealant as appropriate. 5. Lift the third member into the axle housing and shove it into the studs. 6. Install and torque the hardware. 7. Re-install the axle shafts and finish the remaining vehicle re-assembly steps. (and thrust block, if used) are in place and that the springs are working properly.
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Your LOCK-RIGHT installation should now be complete. As a preliminary test, rotate the tires back and forth (transmission out of gear and driveshaft free). The drivers should randomly unlock and “click” as the tires move. Note that the tires will NOT lock together—this easy-unlocking characteristic is a unique feature of the LOCK-RIGHT and is perfectly normal. (do not change from side-to-side if they are radials).
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5. Rotate the first tire in the reverse direction and hold it; repeat step 3, rotating the other tire in the forward direction. 6. Repeat steps 2-4, rotating and holding the second tire to lock the second side. Warranty Information The Warranty is contained in the Vehicle Owner’s Manual that is supplied with your new LOCK-RIGHT. Consult this manual for complete warranty information.