I finished up the elocker swap last night. I picked up a complete axle assembly from a wrecked '99 Highlander (green, 5 spd, elocker, 143K miles, no rust at all). It had the 4.1 gears I need for my 5 speed. The good news - the locker works great. :driving:
I used Inchworm's wiring kit and added a Marlin Crawler elocker guard. While I was in there, I put in new axle seals.
Random notes on the install, in case anyone uses this in the future:
- I used 1/8" vacuum tube to extend the locker breather, and routed it up next to the gas cap next to the rear diff breather. Thanks to Nelsonmd for his help here.
- The Inchworm wiring kit was pretty easy to use; it uses trailer wiring to connect the switch to the locker. Comes with everything you need, including switch, light, resistor, connectors, etc. I bought a crimper for the job. Only one issue - the fuse tap provided does not fit the mini fuses the T4R uses. I had to buy an add-a-fuse separately. Use a lighter on the shrink tubing.
- The Inchworm kit acts like a factory kit with the blue wire mod. You can enable the locker at any speed, in 2wd, 4hi or 4 lo. I think I will pick up a different switch to protect against accidental engagement (and my kids).
- I was able to lower the old axle housing and raise the new housing myself using ratcheting straps, a furniture dolly, and two 4x4's. Doing this job solo was pretty easy.
- You don't need to remove the sway bar, just disconnect it from the axle housing and loosen the end links.
- Thanks to BigFishAllDay - his build thread and notes on the locker swap were helpful. Also thanks to Nelsonmd for his input on extending the elocker breather tube.
Now some pix. First picture is the old housing, hanging from the straps & ready to lower onto the furniture dolly.
The gaping hole...
New axle assembly installed
Marlin Crawler elocker guard
Locker breather tube extended next to gas cap and rear diff breather tube.
Inchworm switch and light. I plan to pick up a different switch to protect against accidental engagement (and my kids).
