Hero Locker

I been thinking for a long time to create my own rear locker.

Since i have an LSD rear diff i thought of swapping the 8 clutch plates (4 on each side) with 2 thick impax supreme steal plates.


Left side impax supreme plate measured cutted by water machine
Right side stock 4 clutch plates from one side of the diff

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But first i will have to explain the parts of the LSD diff so everyone can understand.

Here is the parts of the rear LSD diff

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from left to right


Case, clutch plates, ring that hold the clutch plates, side gear

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4spider gear, 3 gear shaft

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side gear, ring that hold the clutch plates, case cover

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Now we focus on this parts side gears, clutch plate ring holder, clutch plates

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Here we have the 4 clutch plates 2 with inner teeth two with outer teeth.
The inner teeth hold the side gear and the outer teeth hold the clutch plate ring holder.

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This part is on both side of the rear LSD diff.

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Now i swap the 4 clutch plates with a singe 6 mm thick water cutted impax supreme plate.
On both sides
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And here we have a FULL TIME LOCKED locker

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Before fitting back again we will have to make sure that the pinion shaft holder is not broken.
If its broken then we just have to take off and not use it at all.


Center part of the 4 spider gears
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Mine was broken so i took it off
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Now you will notice 2 extra parts on its side of the deaf
2 preload shims
2 very thin shims

We place them back again on our new laser cutted steal plates (two on each side)

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we close the case and vouala now we have a full time locker instead of welding the rear diff and destroying our diff.

Of course all of these stuff need to be done by a mechanic or someone that has the knowledge and the tools to do that.

I have used the internet and the right tools so i can put back again all parts by marking them

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and using a torque tool with the manual also.

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Here are the results




A good website to learn how to play with your diff its this one here.
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This mod can be done in any LSD but not on a rear open diff you must weld the side + spider gear together.

In the future i will try to design and machine some new impax supreme plates that will lock and unlock
manually.

Oh i forgot to mension that its cost me 50 euros since i did the labor by myselft.

Bello , economico , ma così si ha sempre il differenziale bloccato al 100 %.....o sbaglio ? In pratica si eliminano i dischi frizione che trasmettono la coppia in caso di slittamento .

FULL TIME LOCKED locker Essì blocco sempre al 100% al posteriore. X uso misto non è il massimo ma in off

No problems for 9 months and 5.800 kilometeres offroading and town.

Its very easy to make it manually (like OX-Locker) but i dont have the time and money to finish it.

beh comunque hai fatto un bel lavoro ...complimenti !

hallo Heroicentaur!
i remember i have seen your mod on the warfs website.
i works great but really don't you think it will cause some extra stress to the axles on the tarmac?
if this will be made possible to lock and unlock will be the best locker for our ferozas...

on my side, i have used the fact that we have 2 drums on the rear axle (not as some suzuki that have the brake drum on the propeller shaft)
so i added a lever and use to lock the wheel that loses traction to pass the twist where my escursion is not sufficient.

my sistem is absolutely useless when on mud but for the cost of 20 euros and 1/2hour of work can get me out from some troubles

p.s. any ideas for the front diff?

Hi Heroicentaur!

Can you please try to explain all missing job and parts to make this lock a "manual" one?

Thanks!

Any way, very good job!

See you!

Hallo, what you Shared is extremely interesting. As already asked by Andrea and other friends, would be usefull if you explain us how to make it lock/unlock. Maybe we could collaborate from our side and make it complete and available to all the Feroza's lovers at an affordable cheap cost.
Best regards from all of us

I will try to make a 3D drawing to show you how it will work.

I have found a machine shop (friend of mine) who can create Version 1 and see if
the ON/OFF locker will last in offroad.

In the tarmac the stress isnt that big (i have Malatesta Kaiman 30") and for about 9 months
i havent brake anything in the rear diff

Watch two videos of how my RED ROZA goes in offroad with Hero Locker

Thanks in advance Heroicentaur!

I've a little knowledge about Mercedes G Klass diffs locking system.
And that's the reason why I prefer having a manual one instead a fix-locked one (ehm... You know... experience by mistakes... I've already rolled-over my old G-Klass... ).

A 3D drawing will be very, very appreciated!

A Feroza (or a Freeclimber II like mine...) whit a rear (and, maybe, a front one...) diff lock will be almost unstoppable!

Best regards!