6
7
Final Installation Steps – Carrier in vehicle
• Install the cross pin shaft and retaining pin.
• Finish assembly by reconnecting brake lines, backing plates, tires, etc.
• Check installation by putting the vehicle in gear and in 4wd if installing in a
front application.
• Rotate one tire forcefully until it stops against the drivetrain. This must be
done in both directions on each side.
• Have a second person rotate the opposite tire in the opposite direction, It
should unlock and spin.
• Your Spartan locker should make a clicking sound as the teeth move over
each other. If this sound is not present, or you cannot get the teeth to disen-
gage at all, check your work.
• Once everything is correctly installed, and the locker has been tested, attach
the differential cover (if your vehicle has one) using a gasket or black RTV
silicone and tighten all the cover bolts.
• Add gear oil.
Final Installation Steps – Carrier out of vehicle
• Thoroughly clean the housing.
• Place the carrier cares on same sides they were removed from.
• Install the carrier into the housing. If outside carrier shims were present,
install them into the same sides they were removed from.
• Replace bearing caps to their correct sides, torque down bolts to the proper
amount. Consult shop manual for the torque specification.
• Finish assembly by reconnecting brake lines, backing plates, tires, etc.
• Check locker operation as described in Final Installation Steps – Carrier in
vehicle.
• Once everything is correctly installed, attach the differential cover (if your vehicle
has one) using a gasket or black RTV silicone and tighten all the cover bolts.
• Add gear oil.
**Note about tire diameters**
For safety and long life of your Spartan Locker, it is important that your tire di-
ameters are as close to identical as possible. Differing tire sizes can cause pre-
mature wear to your Spartan Locker, shortening its life and causing possible
damage to your differential. Measure each tire to make sure that they match
from the ground to the top of the wheel, adjusting tire pressure as necessary.
Note about your carrier: Before beginning to tear down your differential,
please be aware that the Spartan Locker is designed to fit open carriers only. It
will not install into any type of limited slip carrier.
Note about thrust washers: This Spartan Locker does not use the side gear
thrust washers. Attempting to install or operate the unit with thrust washers
present may damage the unit or your case.
This Spartan Locker design comes with the following components: Figure 1-B
• Two (2) Drivers
• One (1) Long cross pin shaft
• Two (2) Short cross pin shafts
• Four (4) Alignment pins
• Four (4) Springs
• Two (2) Spacers
Preparing the vehicle for installation
Take the following steps to prepare your vehicle for installation:
• Block the vehicle’s tires, and place the transmission in neutral.
• Loosen the lug nuts and jack the vehicle up.
• Make sure that the vehicle is securely resting on jack stands.
• Remove the wheels; disconnect the brake lines and emergency brake cables.
• Slide out both axles to provide enough clearance to remove the carrier, if needed.
• Remove the dropout from the axle housing.
Suzuki Samurai Installation Manual
