HDJ81 Diff Lockers

[cruza1991]

Got a pair of diffs from a '96 HDJ81 with the factory electric lockers but the alloy locking motors were badly corroded, and I didn't want to pull all the electrics out of donor vehicle, so I converted them to air cylinders, and put them into my '91 HDJ81. The setup works real well.
I now have a wee problem, after a couple of outings I have stripped the teeth off the front pinion, and I mean stripped. It had a tendency to bind up slightly which I put down to having 35" Kumho 833's on the back and 35" Kuhmo Venture MT on the front, I "assumed" I had a slight difference of diameter.
On stripping the front diff and comparing it to the original open one, I have different ratios!!! The '96 locking type is 41:11 (3.727:1), the original '91 is 41:10 (4.1:1) The back ends then got checked and it's a 4.1:1 both in the '96 locking one and the '91 original LSD.
My cruiser is a part time 4WD, has free wheeling hubs on the front whereas the '96 was a full time 4WD
Has anyone struck anything similar?? or has the diff ratios been dicked around with somewhere along the way
I have put the original 4.1 crownwheel and pinion into the locking carrier andit fitted and setup OK, so it's going back in tomorrow night.

Any info please?????

[mayday]

That dosent seem right, If the diffs were a pair you would want them to be the same ratio. I think your lucky its part time 4wd or the damage would be worse! Im keen to see a pic of your air ram setup, The electric one i put in the back of mine always plays up.

[cruza1991]

Email me offline and I can run you through what I did.
cruza1991@yahoo.com

[sig]

sounds like someone has given you a mismatched pair .The 4.1 will be out of a diesel and the 3.7 will have come from a petrol .you could swap your original front 4.1 crownwheel and pinion in to the stripped locker head .probably needs someone with the right tools and shims to do it thou .or just put your open 4.1 back in thr front and just run the rear locker only.

[cruza1991]

I've got the whole donor vehicle here and it was driving OK on the road with the diffs the way they were. I've already fitted the 4.1 into the carrier and it setup with preload and backlash ok. Ready to jump back into the hole tomorrow night.