PARTS NEEDED:
ELECTRIC LOCKER OEM GASKET
$5.86 (PART# 42181-60050)
WIRING HARNESS OEM
$38.73 (PART# 82164-60012)
DIFFERENTIAL (OBVIOUSLY)
$800.00 OR LESS FOR THE DIFFERENTIAL AND
$450.00 OR LESS FOR THE 5.29 GEARS AND INSTALL
FACTORY OR HOMEMADE CONTROL BOX
$50.00 FOR THE OEM BOX FROM THE JUNKYARD
$15.00 FOR THE OEM PLUG FROM THE JUNKYARD
SWITCH OF YOUR CHOICE, FACTORY OR OTHERWISE
$20.00 FOR THE OEM SWITCH FROM THE JUNKYARD
$15.00 FOR THE OEM PLUG FROM THE JUNKYARD
TWO FACTORY 111mm STUDS OR READY-ROD CUT TO LENGTH
$3.72 FOR TWO STUDS (PART# 90116-08330)
INSTALLATION:
I STARTED BY GETTING THE FRONT AXLE OUT FROM UNDER MY TRUCK. I TOOK EVERY THING OFF OF THE HOUSING TO MAKE IT MORE MANAGABLE AND REPLACE ALL THE SEALS AND BEARINGS WHILE I HAD IT APART. AT THIS POINT I PULLED THE RIGHT THREE STUDS OUT AND OVERLAID THE FACTORY GASKET. I SCRIBED THE OUTLINE OF WHAT MATERIAL NEEDED TO BE REMOVED. I THEN GOT OUT THE GRINDER AND MADE THE BIG NOTCH TO CLEAR THE LOCKER FORK AND WIDENED THE RING GEAR NOTCHES. AT THIS POINT I DROPPED THE DIFFERENTIAL IN THE HOUSING TO SEE HOW IT FIT AND TO ALLOW THE ADJUSTER NUT TO MARK THE DIFF COVER SO I KNEW WHERE TO POUND OUT THE DIFF COVER. I BEAT THE SNOT OUT OF THE COVER WITH A HAMMER AND TEST FIT IT AGAIN. NEXT I DECIDED IT WAS TIME TO TORCH OFF ALL OF MY EXTRA FACTORY BRACKETS THAT I WON'T NEED ANYMORE. (EX. STEERING STABILIZER & SWAY BAR BRACKETS). THEN IT WAS TIME TO BREAK OUT THE WELDER. I WELDED AROUND THE EDGE OF THE GASKET RING NEAR THE TOP HOLE FOR THE 111mm STUD, GROUND THE WELD DOWN AND FILED IT TO GET IT SMOOTH AND FLUSH. THEN I DROPPED THE DIFF. IN PLACE AGAIN AND PUT SOME GREASE ON THE END OF THE FOUR STUDS AND DROPPED THEM INTO THE APPROPRIATE HOLES TO MARK WHERE I NEEDED TO DRILL AND TAP FOR THE NEW STUDS. GETTING THE HOLES DRILLED PERFECTLY STRAIGHT WAS THE HARDEST PART OF THE WHOLE PROCESS FOR ME. ONCE I GOT THE STUDS IN RELATIVELY STRAIGHT I BOLTED THE DIFF. DOWN AND STARTED CLEARANCING THE PLATE THAT HOLDS THE SHIFT FORK GUIDE SHAFT IN PLACE. YOU MUST GRIND IT DOWN AND USE A BOLT WITH A SHORTER HEAD OR COUNTERSINK IT TO CLEAR THE LEAF SPRINGS.
