Front Locker Tear Down

[Wilsonsinak]

I recently had issues with my front locker not engaging. I could not find any pictures of the Power Wagon front locker taken apart. When I took it apart it had very small pieces of metal in the locker where it slides to engage and disengage. Once these where cleaned out it worked perfectly.

Dirty and you can see the small pieces of metal in this picture.



Nice and clean.



Top half of the locker cleaned up.



Internal parts of the locker and the actuator.



Unlocked



Locked



Here is a link to a video of the front locker engaging and disengaging.

https://youtu.be/LUB7WJ-Nlg0

Hopefully this information can help somebody out.

Tim

[Reloaderguy]

Thanks for posting pictures. Did you have to press off the bearings to get it apart?

[Wilsonsinak]

Thanks for posting pictures. Did you have to press off the bearings to get it apart?

I had to pull the bearing off to get the actuator off. You could leave the bearing on and not remove the actuator but I had trouble getting the locking mechanism to slide out so the actuator was in the way of me pushing it out.

[DamageWagon]

Thanks for the pics, very cool! I wondered how the locker worked.

[nts007]

Nice job! This should get archived. I too was unable to find that detail.

[Colibri]

Good work sir! Could you tell where the metal chips came from that were interfering with the locker? My front carrier case had started to crack from repeated shock loading I guess, and I found some little bits like that.

[RustyPW]

[Bill2014]

That's a cool video - nice job.

[Wilsonsinak]

Good work sir! Could you tell where the metal chips came from that were interfering with the locker? My front carrier case had started to crack from repeated shock loading I guess, and I found some little bits like that.

The metal came from the corners of the dog legs that lock the diff up. The locker must have been engaged while the tires where spinning.

I loaned the truck out to a friend and it came back with bad inner and outter axle shafts and I parked the truck at that point while I gather parts. It was parked for four months.

So since i had to replace the axle shafts I decided to upgrade the truck. So I went with chromoly Yukon shafts, 5.38 gears, hydraulic assist steering, 4th gen steering box that I tapped, new unit bearings for the front axle, rear axle swap to a 11.5 with an arb, new steel rear driveshaft, on board air, cb radio, DV8 beadlocks, swapped from 40" swampers to 40" Pro Comp MT2's, and a couple other small things. I listed out all the upgrades just to help explain why the truck was down for four months.

When I did the repairs to the front axle I didn't know there was an issue with the front locker, because when I loaned the truck out the locker worked fine so I didn't tear it apart to clean it. It wasn't until I got the truck back together that the locker wouldn't engage so I started trouble shooting it and found the metal.

[olyelr]

Good work sir! Could you tell where the metal chips came from that were interfering with the locker? My front carrier case had started to crack from repeated shock loading I guess, and I found some little bits like that.

The metal came from the corners of the dog legs that lock the diff up. The locker must have been engaged while the tires where spinning.

I loaned the truck out to a friend and it came back with bad inner and outter axle shafts and I parked the truck at that point while I gather parts. It was parked for four months.

So since i had to replace the axle shafts I decided to upgrade the truck. So I went with chromoly Yukon shafts, 5.38 gears, hydraulic assist steering, 4th gen steering box that I tapped, new unit bearings for the front axle, rear axle swap to a 11.5 with an arb, new steel rear driveshaft, on board air, cb radio, DV8 beadlocks, swapped from 40" swampers to 40" Pro Comp MT2's, and a couple other small things. I listed out all the upgrades just to help explain why the truck was down for four months.

When I did the repairs to the front axle I didn't know there was an issue with the front locker, because when I loaned the truck out the locker worked fine so I didn't tear it apart to clean it. It wasn't until I got the truck back together that the locker wouldn't engage so I started trouble shooting it and found the metal.

Hahahaahah, and all it NEEDED was inner and outer axle shafts lol....

[Wilsonsinak]

Good work sir! Could you tell where the metal chips came from that were interfering with the locker? My front carrier case had started to crack from repeated shock loading I guess, and I found some little bits like that.

The metal came from the corners of the dog legs that lock the diff up. The locker must have been engaged while the tires where spinning.

I loaned the truck out to a friend and it came back with bad inner and outter axle shafts and I parked the truck at that point while I gather parts. It was parked for four months.

So since i had to replace the axle shafts I decided to upgrade the truck. So I went with chromoly Yukon shafts, 5.38 gears, hydraulic assist steering, 4th gen steering box that I tapped, new unit bearings for the front axle, rear axle swap to a 11.5 with an arb, new steel rear driveshaft, on board air, cb radio, DV8 beadlocks, swapped from 40" swampers to 40" Pro Comp MT2's, and a couple other small things. I listed out all the upgrades just to help explain why the truck was down for four months.

When I did the repairs to the front axle I didn't know there was an issue with the front locker, because when I loaned the truck out the locker worked fine so I didn't tear it apart to clean it. It wasn't until I got the truck back together that the locker wouldn't engage so I started trouble shooting it and found the metal.

Hahahaahah, and all it NEEDED was inner and outer axle shafts lol....

The perfect reason to upgrade!!

The difference from the stock 4.56 with 40's to the 5.38's with 40's is huge. The truck drives better than stock now with all the upgrades.

[olyelr]

The perfect reason to upgrade!!

The difference from the stock 4.56 with 40's to the 5.38's with 40's is huge. The truck drives better than stock now with all the upgrades.

I bet. That is quite a list of notable upgrades for sure. Now get to updating the picture thread with some new adventures!

[Colibri]

Man, I would be pissed that it came back screwed up and happy I had an excuse to upgrade lol. Truck is looking great these days, really like the new wheels and tires btw

[flattire]

Note to myself: Never loan truck out.

[Retired BLM Rig]

Note to myself: Never loan truck out.

Especially if you have a friend like Biff Tannen!

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