I installed an Aussie Locker in the rear axle of my 1993 FZJ80 today. I found the instructions a little disorganzied, but the install was easy nonetheless.
Here are some photos of the install for those who are allergic to bananas
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1. Follow the instructions provided by Aussie Locker. These pictures and instructions are only additional help.
2. After the rear axle is safely supported on jack stands, you need to pull the rear axles out a few inches so you will be able to remove the third member from the axle.
2A. Undo the flange nuts, remove the flat washers, and GENTLY tap the sides of the flange to get the cone washers to release. You can do this without removing the wheels, but if the cone washers wont release, you'll need to remove the wheels to get a better angle on the flange. The cones will eventuall come loose, and probably shoot out at you.
2B. Pull the axle out 4-5 inches.
3. Now you need to remove the third member.
3A. Disconnect the drive shaft at the third member and tie it up out of your way. Or, take the whole shaft off, take the opportunity to lube it, and set it aside.
3B. Remove the nuts and get some help to remove the third--the whole differential, carrier, ring, and pinion are in there--it's heavy.
4. If you're not sure what you're looking at, here ya go:
5. Remove the pinion shaft pin, the pinion shaft, the spider gears and their cupped thrust washers, and the side gears and their flat thrust washers.
6. Check out your Aussie Locker. Not many parts:
7. Put a little MP grease on the side gears--both sides of both gears--and put a flat thrust washer on the axle end of the axle gear.
8. Put the axle gears in the carrier where the side gears used to be. (The grease should help hold things together.)
9. Put some grease on the spacers, and place them on the axle gears.
10. Carefully slide the pinion shaft back in between the spacers--just support the pinion shaft, rather than putting the pinion shaft pin back in.
11. Now you need to measure the clearances between the pinion shaft and each spacer.
11A. Carefully wedge a flat-head screwdriver between the pinion shaft and spacers to fully seat the spacers and axle gears.
11B. Use a feeler guage to measure the clearances. If you're out of Aussie Locker specs, you'll need to replace your side gear thrust washers as appropriate.
12. If you're within Aussie Locker specs, you're ready to put the cam gears in. Grease everything to help it stick.
12A. First put one Aussie Locker pin in each slot on the cam gears. The small nub on each pin goes in first.
12B. Pull the spacers out and put them in the cam gears--arranged so that everything will be pointing the right way when the cam and axle gear teeth are meshed.
12C. Put one cam gear in on one axle gear (the teeth obviously need to mesh). Reseat the spacer by pushing on it.
12D. Put the other cam gear and spacer on the other axle gear. Rotate the cam gear so the gaps align to give you a hole. Stick your finger in the hole to reseat the other spacer.
13. Keeping the cam gears aligned, slide each pin out of its slot where it will insert into a matching hole on the other cam gear.
14. The last thing you need to do is put the little springs in the slots, underneath the pins. The springs will fit in the side of the slot with a little careful help from a screwdriver. The spring will seat onto the little nub on the pin. Be patient and go slow.
14A. Using a dial caliper, take a final measurement of the the clearance between the two cam gears. If you're in spec with the previous pinion shaft-spacer measurement, you should be fine here. If not, troubleshoot according to the Aussie Locker instructions.
15. If you're in spec, you're Aussie Locker is installed. Make sure everything is clean, put on a new gasket, and put it all back together.
16. Don't forget to test the locker per Aussie Locker instructions. Read and follow them exactly.
17. Beverage Break
Hayes
Here are some photos of the install for those who are allergic to bananas
. 1. Follow the instructions provided by Aussie Locker. These pictures and instructions are only additional help.
2. After the rear axle is safely supported on jack stands, you need to pull the rear axles out a few inches so you will be able to remove the third member from the axle.
2A. Undo the flange nuts, remove the flat washers, and GENTLY tap the sides of the flange to get the cone washers to release. You can do this without removing the wheels, but if the cone washers wont release, you'll need to remove the wheels to get a better angle on the flange. The cones will eventuall come loose, and probably shoot out at you.
2B. Pull the axle out 4-5 inches.
3. Now you need to remove the third member.
3A. Disconnect the drive shaft at the third member and tie it up out of your way. Or, take the whole shaft off, take the opportunity to lube it, and set it aside.
3B. Remove the nuts and get some help to remove the third--the whole differential, carrier, ring, and pinion are in there--it's heavy.
4. If you're not sure what you're looking at, here ya go:
5. Remove the pinion shaft pin, the pinion shaft, the spider gears and their cupped thrust washers, and the side gears and their flat thrust washers.
6. Check out your Aussie Locker. Not many parts:
7. Put a little MP grease on the side gears--both sides of both gears--and put a flat thrust washer on the axle end of the axle gear.
8. Put the axle gears in the carrier where the side gears used to be. (The grease should help hold things together.)
9. Put some grease on the spacers, and place them on the axle gears.
10. Carefully slide the pinion shaft back in between the spacers--just support the pinion shaft, rather than putting the pinion shaft pin back in.
11. Now you need to measure the clearances between the pinion shaft and each spacer.
11A. Carefully wedge a flat-head screwdriver between the pinion shaft and spacers to fully seat the spacers and axle gears.
11B. Use a feeler guage to measure the clearances. If you're out of Aussie Locker specs, you'll need to replace your side gear thrust washers as appropriate.
12. If you're within Aussie Locker specs, you're ready to put the cam gears in. Grease everything to help it stick.
12A. First put one Aussie Locker pin in each slot on the cam gears. The small nub on each pin goes in first.
12B. Pull the spacers out and put them in the cam gears--arranged so that everything will be pointing the right way when the cam and axle gear teeth are meshed.
12C. Put one cam gear in on one axle gear (the teeth obviously need to mesh). Reseat the spacer by pushing on it.
12D. Put the other cam gear and spacer on the other axle gear. Rotate the cam gear so the gaps align to give you a hole. Stick your finger in the hole to reseat the other spacer.
13. Keeping the cam gears aligned, slide each pin out of its slot where it will insert into a matching hole on the other cam gear.
14. The last thing you need to do is put the little springs in the slots, underneath the pins. The springs will fit in the side of the slot with a little careful help from a screwdriver. The spring will seat onto the little nub on the pin. Be patient and go slow.
14A. Using a dial caliper, take a final measurement of the the clearance between the two cam gears. If you're in spec with the previous pinion shaft-spacer measurement, you should be fine here. If not, troubleshoot according to the Aussie Locker instructions.
15. If you're in spec, you're Aussie Locker is installed. Make sure everything is clean, put on a new gasket, and put it all back together.
16. Don't forget to test the locker per Aussie Locker instructions. Read and follow them exactly.
17. Beverage Break
Hayes
. 
