P500 Another Torq Locker Install Issue

[futzin]

I'm having a significant problem with installing my locker and didn't want to further hijack BC40's thread. Will add pics in a bit, but my issue is that the locker fits so tightly in the carrier that it is fully compressed. It was a b**** getting it in. Jason's looked easy, so I chalked it up to mine being a Gen 2 unit, but no. I will contact them tomorrow, but I thought I'd put this out to y'all this evening to inform and to maybe figure out if I've done something wrong. I removed all four gears and the two cone washers. The model locker they sent is TL-HP500. Pics to follow, hopefully.

Also, my dumb butt reassembled the diff and reinstalled before it hit me . . . 🤬

Unfortunately, I didn't take a pic with the springs in. They were tough to install, as well. Had to tap on the cross pin to reinstall, but not very hard.

 

[MB_Rider]

Can't say I had any issue getting mine installed, it fit in there nicely but I bought mine back in the fall (October I think). I know those little springs needed a fair bit of force to compress them enough to make them go into that little slot. I pushed down as hard as I could with my thumb and then used a punch to push them into place once both ends were somewhat in.

Did yours have this much space between the two middle pieces after you were done? ^^^

 

[futzin]

That's just it . . . I can't remember, sad to say.

To get the last piece to slide in, I had to slowly tap it with a hammer and wood chock, it was so tight.

 

[Mudder]

It should just have clearance for the teeth to ride over each other (looks like it does to me). “Tapped“ mine with rubber hammer.

 

[futzin]

I appreciate the response. No way, no how it was gonna just slide in like in Jason's video. Tried different combos, no different. Finally very lightly and slowly tapped on it to get the last piece to seat. I've reinstalled into the buggy, but haven't filled it or re-installed A-arms yet. Don't know if I should take it apart again for inspection or if I should finish the install and test it. I figure if it's too tight, then it won't ratchet and will be locked full time?

 

[Mudder]

A larger image. Maybe I installed the springs after it was inside. Don’t remember for sure.

 

[906UP]

I appreciate the response. No way, no how it was gonna just slide in like in Jason's video. Tried different combos, no different. Finally very lightly and slowly tapped on it to get the last piece to seat. I've reinstalled into the buggy, but haven't filled it or re-installed A-arms yet. Don't know if I should take it apart again for inspection or if I should finish the install and test it. I figure if it's too tight, then it won't ratchet and will be locked full time?

That is correct, to test have someone hold one wheel stationary while you turn the other, you should hear it "ratchet".

 

[906UP]

It's been a while since I installed mine, I got one of the first they made, I do remember its a bit like a Chinese finger puzzle......it will only go together in one order-one way.

 

[Mudder]

Can't say I had any issue getting mine installed, it fit in there nicely but I bought mine back in the fall (October I think). I know those little springs needed a fair bit of force to compress them enough to make them go into that little slot. I pushed down as hard as I could with my thumb and then used a punch to push them into place once both ends were somewhat in. View attachment 194261
Did yours have this much space between the two middle pieces after you were done? ^^^

Did you pre-lube it before installing? Looks very clean. LOL

 

[futzin]

OK, I spoke with Cora at Torq Masters. Short version, should be just fine.

In late March, about a dozen P500 lockers went out that are very slightly larger than normal. She assured me that it will not affect the locker's operation at all. She mentioned that tapping with hammer would be necessary, which is of course what I had done.
Cora: "Finish it up and go have fun!"

Thanks guys, for the help and input.

 

[MB_Rider]

Did you pre-lube it before installing? Looks very clean. LOL

Lubed and rubbed, lubed and rubbed some more hahahaha just kidding it only had 60km on the odometer. Bought it in September and only used it to tow my nieces around on a sled. Hopefully this Covid-19 business doesn't interfere for my first summer ride!

 

[futzin]

Just passed the spin test!

 

[70Bones]

Just passed the spin test!

any unusual noises or clicking?

 

[Mudder]

Did your front axles go back in all the way? Some guys reported a gap.

 

[70Bones]

Did your front axles go back in all the way? Some guys reported a gap.

Good question, and I wonder if they'll come out without breaking the spring clip...

 

[futzin]

Yeah, there's a gap. I'll get pics another time. Headed to lake (hopefully) tomorrow to open camper. I removed one circlip and tightened it, but when I put it back on it went back to the same size as before so I gave up on that. I saw Cora's input that it isn't needed on a Gen 2 locker.

any unusual noises or clicking?

No unusual noises. There was the audible ratcheting sound I was hoping for! (especially after the tough fitment)

 

[906UP]

Sounds like you're good to go!

 

[futzin]

Sounds like you're good to go!

Gonna attempt a winch install while the front is torn down. Not stuff I'm used to doing, but what the hey. The interweb has my back. Had a couple of friends on standby in case of trouble on the locker, but I muddled through. Screwed up a time or two, but nothing too bad, yet.

I'm REALLY anxious to test the locker.

 

[futzin]

Here are pics of the gaps; they are uniform at least.

 

[Mudder]

Congratulations on the P500 upgrade. Nothing like all 4 wheels pulling in the rough stuff.