I have all of the parts gathered together and have begun the initial stages of the '97 e-locker in an '87 axle mod. Really all I did tonight was spray everything with penetrating oil and drain the diff fluid. The real work begins tomorrow bright and early.

I'll be disassembling the whole rear axle down to the housing, then haul it to Denver where a friend is letting me borrow tools. I lack a drill press, welder, brass drift and tap and die set. If I get the old stuff apart in time, I should be locked and ready to rock by Saturday.

Wish me luck. I've never done anything this big before. <img border="0" alt="[Baby]" title="" src="graemlins/baby.gif" />

Very cool Matt! Take your time, measure 6 times cut once <img border="0" alt="[Hillbilly]" title="" src="graemlins/notooth.gif" /> and have a few beers when it's all done - and be sure to let us know how it goes!

</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Originally posted by little_joe:
<strong>Take your time, measure 6 times cut once <img border="0" alt="[Hillbilly]" title="" src="graemlins/notooth.gif" /> </strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">How true! I like working with steel but it is very unforgiving of any mistakes...

I'm in the same boat...I have never done anything like this before.

I have the wiring done and will install the third member in early May. I even managed to figure out how to get the factory dash switch to light up at night. I love using factory stuff.

Good luck on your install.

</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Originally posted by jx94148:
<strong>Wish me luck. I've never done anything this big before. <img border="0" alt="[Baby]" title="" src="graemlins/baby.gif" /> </strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Very cool! Installing my e-locker was my first "big" project too. I have a writeup on my website describing the project. My only advice... take you time drilling the holes for the new studs. everything else is cake.

It took me 3 hours to get the axle housing out. I hope that is the hardest part in terms of effort and brute force to be exerted. The U bolts took no less than 1,000,000 foot lbs of force to get off. I've got lots to do today still so I better get going. <img border="0" alt="[Fro]" title="" src="graemlins/rainfro.gif" />

Ah, so close and yet so far. While tapping threads in the last of 4 holes, the tap tool broke in the hole. <img border="0" title="" alt="[Mad]" src="images/icons/mad.gif" /> We tried to drill it out but its harder than any bits I currently own. Anyone know what I need to get this out?

Other than that everything went smoothly. My friend Jeff's neighbor has a huge 220 volt welder. I guess sometimes its not what you know but who you know. We only needed a weld for the lower of the two outer left holes. The area for the top one was graciously done for us at the factory 15 years ago. There was lots of extra metal there. <img border="0" title="" alt="[Smile]" src="images/icons/smile.gif" /> We filled the old holes by thread locking the old studs in and cutting them off. I got 2 short and 2 long 8mm 1.25 pitch bolts from good old Ace Hardware. Forget about trying to find metric ready rod like the article says.

Tomorrow's agenda:
1. Visit Ace again for a small bit that will cut the tap and to try to get them to replace the tap that failed on its 4th use.
2.Bolt everything back in place.
3.Bleed the brakes.
4.Wire up the SOB.
5.TEST TEST TEST <img border="0" title="" alt="[Big Grin]" src="images/icons/grin.gif" />
6.Post the pictures.

<small>[ 29 March 2002, 12:19 AM: Message edited by: jx94148 ]</small>

I'd like to see how it turns out. I am planning the same thing when I SAS and am currently shopping for the diffs.

</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Originally posted by jx94148:
<strong>I got 2 short and 2 long 8mm 1.25 pitch bolts from good old Ace Hardware.</strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Sounds good Matt. If you are using the factory ECU, I recommend hooking up the 4wd circuit (pin 8 on the plug) to a toggle switch and run the other end to ground. The locker won't lock until pin 8 sees ground. This way you have the capability to use the locker in 2WD if you desire and yet the diff can't be locked at 70 mph if someone accidently hits the diff lock switch. (This assumes of course that you turn off this master switch in normal driving.)

BTW, what length bolts are you using? I may buy some just in case the studs don't work out.

I'm copying this wiring system that uses an on-off-on 2 circuit switch. Another disabling switch hidden out of reach would be a good idea.

Wiring instructions

The bolts are about 3.5 inches. I had 4 inch at first but they were just a bit too long.

<small>[ 30 March 2002, 10:24 AM: Message edited by: jx94148 ]</small>