A friend of mine just sent me his "slightly used" Powertrax locker for my Dana 35 (yes, Bill, I'll send you links of broken axles ;-)!) I was going to call the shop today to see how much it would cost to install it, and decided to just do it myself instead. Well, it took FOREVER. Really because the instructions stunk (didn't seem like they were for the right locker -- downloaded from the website). And there were a few... catches.
For example, I couldn't use my thrust washers. I had all but given up on the install (couldn't get both couplers in there -- one at a time; both at the same time, with side gears, without, etc.) when I called up my friend and he said he didn't use his thrust washers. Not intentionally -- he just forgot to use them. So I took the thrust washers off of the side gears, and voila, everything fit. And when I say "fit", I mean it was very difficult just to get the two couplers in. Once installed, everything lined up the way it should, with the proper clearances.
Will there be problems with not using the thrust washers? Do I need to get new, but wafer-thin ones? My stock ones were thin to begin with, but were still too thick to use.
Eric
99 TJ SE