How to Install a Lock Right

At the very least, installing a Lunch Box Locker like a PowerTrax Lock Right will require removing the differential cover, draining the gear oil, removing the axle shafts (and C-clips if equipped) and some disassembly of the open differential carrier. We had this 2000 Ford Explorer front axle out of the vehicle, and because of the position of the ring gear and the side gear cross shaft we will have to pull the carrier out of the housing and remove the ring gear from the carrier. Doing this doesn

Removing an axle

Once you have the differential carrier removed from the axle and have pulled the ring gear you can remove the cross shaft that holds the spider gears in the axle. This differential has a roll pin that holds the cross shaft in the carrier. Also, note, you don

remove the cross shaft. On this carrier you

Keep the roll pin, you will need it to hold the replacement cross shaft in place, it needs to go back into the carrier the same direction that it came out.

The cross shaft comes out of the carrier on the side of the carrier where the roll pin is. Use a brass drift and a hammer to remove the cross shaft.

With the cross shaft out of the carrier you can spin one of the side gears and the spider gears will

Here

Here

But wait, theres more! Now that this half is in the carrier you need to add two of the sheer pins to the oblong holes. You can add some grease to keep the shear pins in place until you want to move them. The other side of the locker will need grease or transmission assembly lube on all the parts to keep them in place since they will need to go into the top of the carrier...despite gravity. Add the second side gear thrust washer to the back of the coupler and put it in the top of the carrier.

Now you will need to turn the Lock Right until one of the larger holes (with the shear pin in it) faces you. Use a pick or small screwdriver to push it into the smaller hole on the opposite driver. Then you double up the included springs (one inside the other), add some grease to them, and put one end into the larger hole towards the dropped down shear pin. Use a small flathead screwdriver to compress the top of the springs and pop them into the larger hole. This may seem odd at first, but once you see how the springs seat in the larger hole it will make sense. The springs will push against the shear pin keeping it in both drivers at once.

Repeat the shear pin movement (from large t small hole) and dual spring installation for the remaining three sets of holes. You may have to turn the carrier over to do this. Then align the half moon cuts in the drivers with the hole the cross shaft will fit into and insert the cross shaft. Be sure to get the hole the roll pin fits into parallel to the roll pin hole in the carrier. Drive the roll pin into the carrier and cross shaft.

With the locker in the carrier you can lign up the ring gear back on the carrier (in the same orientation that it came off the carrier) and drive it onto the carrier (use a brass drift and a hammer don