A noob's plea: Destroyed locker housing while removing for rebuild (pics)

[Beej]

Hey folks,

First, the pics:

Broken locker 1

• Beej
• Jun 7, 2016

Broken locker 2

• Beej
• Jun 7, 2016

Broken locker 3

• Beej
• Jun 7, 2016

Broken locker 4

• Beej
• Jun 7, 2016

Broken locker 5

• Beej
• Jun 7, 2016

Broken locker 6

• Beej
• Jun 7, 2016

And the story:

I realized my rear locker was not engaging. Did all the tests. Link to thread with tests here: Testing the rear locker: Dash light just blinks

So, I decided to rebuild. There are wonderful instructions on here from Landtank and others so I figure, what the hey. Bought all my parts from Wits end and the right grease, etc.

What ended up happening was a fight with some stuck bolts trying to get the locker off of the axle and in removing them (penetrating oil, special extractor sockets, lots of banging) I broke the locker housing. It just gave up. It broke like a cracker.

Landtank had warned me to be gentle with the aluminum housing, which turned into a flat out prophecy.

Two things:

1.) Do not make the mistakes I have made. Be gentle with the lockers.

2.) Does anybody have a spare housing or know of how or where I can obtain one? I'll be reaching out to local junkyards tonight but I do feel chances are purty slim. Any suggestions are welcome.

As you can see in the pics, the locker was totally corroded and terrible and some of the magnets had come unglued. It did need rebuilding, thank God. But, until I can get another housing I'm suuuper SOL. There's just a big hole in the side of my rear diff!

Thanks in advance for any replies. Time for ... but probably

-- Beej

 

[Beej]

40+ views and no replies, eh? I suppose no one wants to be the one to say I'm totally screwed?

 

[canman]

I feel your pain. Had to replace mine because of too much corrosion where the o-ring groove was. It was a beech to get off as well. Forget the beer, start with some rum.

[EDIT:] Cut out a piece of 1/4" flat stk with some mounting holes to cover up the opening until you get it sorted out.

 

[Pin_Head]

I don't see anything destroyed, but if the aluminum housing is cracked or broken, it can be welded.

 

[97CruiserJoe]

I don't have lockers but it looks like you can still use most of the parts. Looks like it was just apart because you unbolted it. Then again I don't know how a good locker should look like. Sorry man, at least you have lockers you can rebuild.

 

[LandCruisinMy93]

@Beej, yeah, you screwed the pooch alright! But @Pin_Head is correct, I would either weld it myself or find someone who can. There is special welding rod you can buy to weld aluminum with a MAPP gas/ propane torch. Might go that route. Alumaweld at harbor freight actually does really well and is inexpensive. I would gut the housing, clean it really well and degrease it. Then use a stainless steel wire brush and clean it up really well. Afterwards clean it again and use a file or a dremel and bevel the edges of the break. Find a 1/2" thick peice of steel big enough to bolt the hosing down to and drill it out and bolt the housing to it so it won't move around or warp too much.

 

[69LC]

We had the same problem with out rear actuator housing except that the inside of the motor and gear housing were also severely corroded beyond repair. The diff will be wearing a block off plate until I can find another actuator housing or afford a Harrop.

 

[Beej]

Wow, didn't think to repair it. Thanks for the suggestions!

I'll grab the pieces and snap a pick and post tomorrow. See what we're working with.

I have some brass wire wheels and cups for the Dremel so I think I could get it pretty well cleaned up.

 

[Douglas S]

I don't think it will weld very well. You may as well give it a try though.


I had to replace mine due to water ingress. Not an inexpensive little unit.

 

[Beej]

I don't think it will weld very well. You may as well give it a try though.


I had to replace mine due to water ingress. Not an inexpensive little unit.

What vendor did you order from for a replacement?

 

[69LC]

When I checked a few months back there was supposedly one in the US for $700. Someone later chimed in that it was gone.

 

[Douglas S]

What vendor did you order from for a replacement?

Partsouq.com, less than $500 USD