In this comprehensive walkthrough, we dive deep into the mechanics of installing the renowned Australian 'LOKKA' locker into a Nissan Pathfinder R51 (2008 to 2012) front r180 differential. From the outset, our journey explores the nuances between different clearance measurements. Spoiler: It's not always as straightforward as the manuals suggest! Discover how we navigated the discrepancies between two sets of installation documents and the challenges that came with it.
Known for its robustness and precision, the 'LOKKA' demands meticulous attention, especially when dealing with spacer clearances, thrust washers, and intercam gears. But it's not all about numbers and measurements. This video takes us on a hands-on adventure, from testing out the initial fits, grappling with the intricacies of the intercam gears, to mastering the art of grinding down thrust washers when no machine shop is up for the task.
So, what exactly is a lunchbox-style locker, and why is it a game-changer for off-roading? A lunchbox locker, like 'LOKKA', replaces the stock differential internals to provide 100% drive to both wheels, ensuring that both tires rotate at the same speed. This is crucial for off-roading because, in uneven terrains, it's common for one wheel to lose traction. With a lunchbox locker, even if one wheel is in the air or on a slippery surface, the other wheel will continue to provide drive, enhancing traction and stability. In essence, it's the secret weapon for those who love to venture off the beaten path and confront challenging terrains.
Though we're not professional mechanics by trade, our years as "shade tree" amateurs have granted us a wealth of hands-on experience. Trust us when we say this: if we can do it, so can you. Dive in, let's tackle this project together, and keep those gears turning!
If you enjoy the video, don't forget to give it a thumbs up! Stay tuned for more (mis)adventures on our channel.
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0:00 - Introduction
0:35 - Opening up the original axle
0:54 - Looking inside the differential
1:21 - Pulling out the passenger side axle seal
1:52 - Removing the intermediate shaft snap rings
2:11 - Removing the bearing caps
2:15 - Pulling the carrier out
2:29 - Carrier spacers and the importance of not mixing them up
2:56 - How to calculate your gear ratio
3:24 - Removing the spider gears
3:43 - Removing the ring gear
3:50 - Using a common 3 1/2" nail as a tool to remove the roll pin
3:59 - Removing the differential cross pin
4:30 - Uh oh, I've got a problem with the cross pin!
5:01 - A new cross pin has arrived!
5:42 - Comparing the new pin to the old pin
5:55 - Going through the components of the Lokka (locker)
6:40 - The critical spacing of the Lokka components
7:02 - The thrust washers
7:32 - Measuring the spaces between the cross pin and the Lokka spacers
8:44 - Rough assembly to test spacing
9:45 - Measuring distance between the Lokka intercam gears
10:02 - Uh oh, another problem! Not enough clearance between the intercom gears
10:21 - What the Lokka documentation tells me what I can do
11:22 - The solution I came up with to grind down the thickness of the thrust washers
12:07 - Setting up the operation
13:50 - Let the grinding begin!
14:34 - Releasing the thrust washer with heat
14:40 - Re-checking specifications
15:24 - Final (?) assembly!
17:52 - Oh no, yet another problem: clearance!
18:02 - A problem of my own making! I just need to assemble the Lokka properly!
18:37 - Re-installing the ring gear, using a thread locker and the proper torque settings
19:29 - Re-installing the carrier and Lokka into the axle differential housing
19:47 - Re-installing the intermediate shaft
20:40 - Installing new axle seals
22:17 - Sealing the access panel with RTV silicone and installing
22:57 - Outro
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