E-Z Locker Installation

		"Although most models of the e-z locker can be easily installed by the owner who is mechanically inclined and has the vehicle--maker's Service manual available, Tractech recommends that a certified driveline mechanic perform the install in that tools of the trade are helpful". Read and follow the vehicle manufactures instructions for: Blocking and jacking up the vehicle Pulling axle shafts Removing the bolt--on carrier Removing the ring gear Measuring backlash Preserving or replacing bearings marking everything as left - right. Separating ring gear from differential case marking across both parts to maintain location at reassemble. Removing standard differential components. Inspecting and washing all parts to be re-used; replacing worn parts. Operation: The e-z locker is designed to let your vehicle operate when one wheel looses traction -- even if it leaves the ground. Unlike a standard differential, the Detroit E-Z Locker differential prevents a low--traction wheel from spinning which greatly reduces drive torque to both wheels. The Detroit E-Z Locker differential replaces standard pinion gears, side gears (rear only) and the cross pins	Parts included in kit: Spring and cap Spacer Dowel pin Clutch Side gear Cross pins Tools and Parts: RTV type sealant 80w-90 gear oil Slide hammer Sockets Wrenches Torque wrench Dial indicator Oil seals Vehicle Performance: "Turning" is different. The outside wheel is coasting; the inside wheel is driving the vehicle. You may hear sounds of the components disengaging and re-engaging, or of the outside side gear teeth passing over the clutch teeth -- especially in cold weather when the lubricant is thicker. You may feel the transfer of torque from both wheels to one wheel and back again; or hear tire "chirp". You may feel pull on the steering wheel going from drive to coast and visa versa -- especially on slippery ground. Make turns using slight throttle rather then coasting.   "Straight" is different. Your new differential takes about 1/4 - 1/2 of a wheel rotation to allow it to operate. This causes a slight delay going from drive to coast and coast to drive. Small steering corrections may unlock one wheel or the other. You may feel steering pull. You may feel slight sideways movement. On a slippery surface, or downhill, slow down with the engine first, then the brakes.
		E-Z Locker Kit Installation     This installation is on a 86 - 88 Samurai. Newer models are similar, but bolts sizes vary.
Disconnect the brake line and E- brake fittings. Soak the fittings with a penetrating oil and rock the fitting back and forth to prevent breakage.		Remove the 19 mm drain plug bolt and the 17 mm fill plug bolt and drain the old gear oil into a suitable container.
Remove the four 12 mm (1986 - 1988) bolts on the propeller shaft.  Tie the drive shaft up out of harms way.		Loosen and remove the 12 mm bolts that hold the carrier assembly to the axle housing.
There are four 12 mm nuts and bolts that hold the backing plate to the axle. Remove these bolts and break the seal between the axle and the backing plate.		Carefully remove the axle from the housing. There is an axle seal protector just inside of the seal. Hope you bought new seals when you purchased your locker. It would be a shame not to change them at this point. You will need a slide hammer to remove the axle and bearing. Check for worn axle bearings especially on the long axle.
To break the seal on the differential position your floor jack under the propeller shaft flange and apply pressure on the housing until the housings separate. There is no good way to hold it up, I let the pig rest on the jack and pull both jack and differential out from under the truck at the same time.		Mark the carrier bearing caps. It is very important to maintain correct side to side placement of all parts! The carrier is held in place with four cap bolts. The adjusters are retained with two 12 mm bolts. Loosen the adjuster bolts. Loosen and remove the 4 large bolts for the carrier. Remove the carrier from the housing to the work bench.
Mark the carrier bearings. It is very important to maintain correct side to side placement of all parts!		Remove the ring gear for access to the cross pins.
Mark the carrier top and bottom, remove the cap bolts and the top cover.		Remove the top side gear. Note the position of the shim, remove the shim for use on the new side gear. Maintain the proper side to the gear.
Pull out the cross pins, center spacer and side gears .   Clean carrier and bearings. For easier assembly coat all parts with grease.		Install the shims removed in a earlier step to the side gears. Place the side gear and thrust washer into the flanged half of the case.
Grease the springs, spring caps and dowels.		Place a clutch and spacer on top of the side gear. Insert spring cap assembly into each of the elongated holes in the clutch, with cap facing out. Insert a dowel pin onto each of the two round holes of the clutch. Repeat for second clutch.
Install the stock spacer and three cross pins.		Install 2nd clutch and top side gear with shim.
Test the fit of the clutch assembly. Make sure there is free movement in the springs and dowels.		Replace the cap screws re-aligning the match marks made during disassembly. Use a quality thread locking compound.
Install ring gear.		Install carrier.
Detroit E - Z Locker Kit		Complete the assembly according to the vehicle / axle manufactures instructions. Attaching the ring gear, assembling ring gear into the carrier case. Cleaning surfaces and inside of axle housing. Checking backlash, shimming as required. Torque bearing caps. Re-install axle shafts and back plates. Adding gear oil and test drive.