I've read where several people here have pulled their Aussie Lockers because of various reasons but no one has been very specific.
I've got an 08 X with 20k miles that's never been wheeled hard and I'm on my 2nd Aussie Locker with the same issue.

When I turn I hear the ratcheting (normal) but I also get a Ka-Chunk sound that feels like the locker locking and unlocking. You can feel it radiate through the jeep, feel it in the steering wheel and hear the sound from more than a block away. It feels like I'm driving over the little reflectors that divide a road when it happens.

All of my measurements were within spec when I did the install both times. I've worked the issue with Aussie and we've not come to a solution yet. They say this is the first they have heard of this issue. That may be the case but I know there's nothing bent or broken in my axle, so I have a real hard time blaming the jeep. I'm hoping there's some of you out there that are having a similar issue and we can find a solution.

Here's a video we took of the sound.. It's 33mb big so it may take some time to download.. Check it out and listen and see if yours is / was making similar sounds.

CLICK HERE FOR VIDEO

 

I have a lock right, sounds the same as mine.

 

Yeah if I didn't have a friend 6 houses down with an 08 JK with the Dana 30 up front and the Aussie locker and have seen that his is silent when he turns I might think it was normal...

 

Mines been doin fine otherwise, but that hard of a clunk worries me too.

 

Thats exactly where I'm at.. It works great on the trail and doesnt make a sound in 4 wheel drive.. Works perfectly.. In 2wd all hell breaks loose.

Well maybe some others will chime in and we can find something common between us that's causing it.

 

I know you say that there is nothing bent or broken in your axle, and you want to think that it's the locker and nothing to do with your jeep, but:

Kinda puts up that little red flag for me.

Have you got a video of it turning in 4wd for comparison?

When the jeep is turning, can you get close enough to tell if the noise is actually coming from the wheel/locker area, (and on one side, or both) or is it possible that it's a binding driveshaft or something?

Anyway, no experience with it, just tossing out some thoughts...

 

I can take a video of it in 4wd and post it.. It doesn't make the sound though so it didnt think it would be useful. The only thing that makes me think it's the locker (or because of the locker) is when I pull it out and put the spider gears back in, it doesn't happen. If I drive it to a Jeep dealer right now and say theres somthing wrong with the Jeep, they are going to tell me to pull the locker.. If the locker is out there is no problem that needs attention.
My buddy when we were filming said it looked like the driveshaft was spinning fast then it would stop and start spinning again. However without hanging someone from under the vehicle it's hard to video tape the driveshaft.
I've compared the slack in my driveshaft to my buddies JK who also has an aussie and they are identical.. We also had very similar measurements on his install.
It feels like every 4th or 5th ratchet that the locker grabs for just a second and then releases.
There may not be anything wrong with the locker, but there may be some differences in the new Dana 30 that locker mfgs havent accounted for and that's why some of us have that ka-chunk sound.

 

Sounds like normal locker ratcheting to me. They all do that on turns. Think about the forces involved. You got what...maybe 3K pounds on the front axle? You bet it's gonna make a fuss when the locker ratchets. Get off the pavement and engage the transfer case and turn. You'll think the axle is breakin in two if that ratcheting upsets you.

 

My Aussie has been doing that since day one. I believe what you are hearing/feeling is a combination of the normal locker ratcheting plus the drive-line lash.


But if you talk to Aussie again and they want to see it in person, have them tell Bill (the pres of Aussie) to get hold of me.
He was there when my Aussie was installed so he knows it was done right.

 

I don't notice my Aussie locker at all unless I turn sharply on a hard surface. Did you use the JK Dana 30 specific version (XD-13227)? It uses a different thrust bearing. You can lift the front end and do a test by rotating the tires when in 2WD and 4WD to isolate the problem. Sounds like the gaps are not right or a spring is not seated correctly.