One of the most useful additions to any trail rig is a locking differential. I had originally planned to put a LockRight locker into Project No-Bucks. As I was about to order, I came across a new locker being offered by Torqmasters, called the Aussie Locker. It appears to be identical to the LockRight, but is supposedly stronger and with less backlash, and for $40 - $60 less money. Assuming this thing works as well as it's supposed to, look for another one of these in the front axle as funds become available.

Start with one open differential.
In this case, it's the 30-spline Scout Dana 44 rearend of Project No Bucks.
Here it is all stripped and ready for the install.

In some applications you can install the locker right into the axle. The ring gear on the Dana 44 is just thick enough that it prevents the cross shaft from sliding out of the differential case. As a result, you must remove the whole ring gear and carrier assembly from the axle. Make sure you mark the bearing caps so you can reinstall them in their proper places.

The manual tells you to use a case spreader, but the ring gear and carrier on this axle popped out with just a little pressure from a prybar. I put a piece of one inch blue housing foam on the ground beneath the axle just in case I didn't catch it when it popped out.

In order to install the Aussie Locker you have
to strip the spider gears out of the carrier by removing the cross shaft. The gears should basically fall out. Save the washers from the spider gears that were on the cross shaft.

Grease each part as you put it in the case. Start with the side gears. Put the thrust washers on the gears, and install the gears in the case.

Next, install the cam gear and spacer on the ring gear side. Before you do this, make sure you put the spring pins in the slots on the cam gear. The cam gear slides into the carrier and up against the side gear. If you use enough grease, the cam gear will stay in place.

Slide the second cam gear in the other side and install the cross shaft. Don't install the roll pin yet, as you may want to take the cross shaft out as you install the springs. Push the pins into the holes opposite of the slots, and install the springs with a screwdriver.

NOTE:I did run into a slight snag while installing the cam gears. When it came time to put the second cam gear in it wouldn't slide into the carrier. No matter which way I tried to put it in, it kept sticking on the top and bottom of the case. I even grabbed a rubber hammer and gave it a couple of whacks before cooler heads prevailed.

I finally took a file and took off a very even amount, less than 1/16" on the top and bottom on the inside of the stock carrier (in red). The locker slipped right in after that. The area affected was about the size of a dime and I don't think it will matter. If it does, I guess I'll be regearing.

I informed TorqMasters of my problem and some thoughts as to what might have caused it, and I received the following email from them:

Joel,

I have received the comments back from our engineers and they agree with
your assessment that it is a casting fluke. However, your pictures will
certainly assist them in confirming this, but they seem to be in total
agreement.

Bill

When you put the ring gear back on, torque the Dana 44 ring gear bolts to 50 ft. lbs. in a criss-cross pattern, and you're ready to put the carrier back in the axle.