Figure 1. The axles were pulled so new bearings can be installed before installing the rear disc brake kit. Upon inspection, the rear axle splines are heavily worn and the axles will have to be replaced. The rear Dana 44 in the 86 CJ7 is a fairly rare option, and no aftermarket axle maker has off the shelf axles available. Custom axles will have to be made for this unit. and Mitchell Differentials was chosen to make the axles for this Jeep. They wil be the alloy axles for strength, which will be good with the horsepower expected from the LS engine.
Figure 2. The new Yukon Gear 3.92 and up open differential carrier. This will replace the worn one on the left. This should insure the Aussie Locker install will be within specifications.
Figure 3. These are all the components in the Aussie Locker. Side gears, spacers, inner gears, and springs and pins. We also purchased a new cross pin, and retaining roll pin.
Figure 4. Here is the Aussie Locker installed in the Dana 44 carrier. Clearances are very tight with the new carrier. The spacer to cross pin clearance was right at .006, which is the minimum clearance. The final gear clearance came in at .146, which is .001 above minimum. We used new thrust washers also, so we expected it to be tight.
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